Dodge - Durango 2wd - Workshop Manual - 2000 - 2000

Factory Workshop Manual Make Dodge Model Durango 2wd Engine and year V8-5.9L VIN Z LDC (2000) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 7 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 8 Power Door Lock Relay: Description and Operation The driver unlock 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9 Power Door Lock Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 13 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 14 Trailer Towing Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Controller Antilock Brake (CAB) EBC 325 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 21 Controller Antilock Brake (CAB) EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 22 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Black 14 Way C1 Black 14 Way Controller Antilock Brake C2 Black 4 Way C2 Black 4 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 23 Controller Antilock Brake: Description and Operation The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a Vehicle Speed Signal (VSS) to the powertrain control module. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. 3. Disconnect the pump motor connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 26 4. Remove screws attaching CAB to the HCU). 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4-4.7 Nm (36-42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 27 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch lbs.). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 32 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 33 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 34 Radiator Cooling Fan Motor Relay: Description and Operation RADIATOR COOLING FAN RELAY - PCM OUTPUT The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103 °C (217 °F). It will then de-energize when coolant temperature drops to approximately 98 °C (208 °F). Refer to Cooling Systems for additional information. Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Refer to Heating and Air Conditioning for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 39 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 40 Blower Motor Relay: Diagrams Power Distribution Center Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 41 Blower Motor Relay: Description and Operation BLOWER MOTOR RELAY The blower motor relay (also referred to as Voltage Reduction Relay or VRR) is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The VRR is used to reduce blower speeds in Heat mode. In non-A/C modes, the relay is de-energized and switches the current flow through an added resistance in the resistor block. When an A/C mode is selected, the relay is energized and the normally open contact is used to bypass the added resistor. The fuse is located in the small relay fuse block that is attached to the Junction Block. The relay is energized by grounding the coil low side with the HVAC switch in any A/C mode. Blower Motor Relay (VRR) Location The blower motor relay is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Refer to the PDC label for blower motor relay identification and location. The blower motor relay (VRR) cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 42 Blower Motor Relay: Testing and Inspection RELAY TEST Blower Motor Relay Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Remove the blower motor relay 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 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 directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 43 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the ON position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. ADDITIONAL RELAY CIRCUIT TESTING - The relay common feed terminal cavity 30 is connected to the low side of the blower motor. When the blower switch is Off and the ignition is On, there should be battery voltage present on this circuit. When the ignition switch is On, the voltage at that point should vary based on blower switch position. - The normally closed contact cavity 87A is connected to the resistor block cavity 3. Check this circuit by turning the blower switch to High and cycling between Heat and A/C modes. The voltage in the Heat mode should be approximately 2 volts. The blower switch must be in High blower speed position during this check. - The normally open contact on cavity 87 is tied to both the resistor block cavity 6 and the HVAC blower switch cavity 6. Check for continuity on this circuit. - The coil B+ contact cavity 86 is connected to an ignition run start feed. Battery voltage should be present on this circuit when the ignition switch is in the Run position. - The coil ground (-) cavity 85 is connected to the HVAC switch cavity 2 as well as the JTEC and A/C high pressure switch. Battery voltage should be present on this circuit when the ignition switch is in the Run position and a Heat mode is selected on the control head. When an A/C mode is selected, the voltage at this point should be less than 1 volt. - If the blower motor does not operate, or only operates in some modes, check for a faulty connection at the VRR, or defective blower motor relay (VRR). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 44 Blower Motor Relay: Service and Repair REMOVAL Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box as described in Instrument Panel. Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Using a short or 90 degree screwdriver, remove the screw that secures the blower motor relay (VRR) to the steel clip in the instrument panel plastic flange. 4. Maneuver the VRR into the glove box opening far enough for access, and disengage the wiring harness from the relay. 5. Remove the relay through the glove box opening. INSTALLATION 1. Position the relay into the instrument panel inside the glove box opening. 2. Align the VRR with the connector and engage the wiring harness to the relay. 3. Align the relay with the steel clip in the instrument panel, and insert and tighten the single screw to 2.2 Nm (20 in. lbs.). 4. Roll up the glove box Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 48 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 49 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 50 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the electronic cycling clutch switch, the low pressure cut-off 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. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 51 Compressor Clutch Relay: Testing and Inspection RELAY TEST Compressor Clutch Relay 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 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 fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 52 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 Audible Warning Device Control Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Audible Warning Device Control Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 102 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 103 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 104 information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 108 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 109 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 114 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 118 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 119 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 120 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center Headlamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 124 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 125 Headlamp Relay: Diagrams Power Distribution Center Headlamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 126 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 127 Headlamp Relay: Description and Operation The headlamp (or security) 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 128 Headlamp Relay: Testing and Inspection The headlamp (or security) relay is located in the Power Distribution Center (PDC) in the engine compartment. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. The driver unlock relay is located in the relay and fuse block on the back of the JB underneath the left end of the instrument panel in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. To test the relay circuits, refer to the circuit descriptions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Terminals Remove the relay from the PDC, JB or the relay and fuse block 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, test the relay circuits. If not OK, replace the faulty relay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 129 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp 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 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-12-2 Horn Relay is located in the Junction Block (JB). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 133 Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 134 Horn Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 135 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 136 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 137 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. The horn 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM ) grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. See the fuse and relay layout label on the inside of the fuse access panel for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 138 Horn Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Horn Relay Remove/Install 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 142 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 143 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 149 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 152 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 153 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 154 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 155 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 156 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 157 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 158 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 159 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 160 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 161 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 162 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 163 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 164 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 167 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 178 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up Central Timer Module: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up > Page 184 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 185 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 188 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 189 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 191 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 192 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 193 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 194 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 196 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 199 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 200 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 203 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 206 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Central Timer Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Central Timer Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 210 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 211 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 212 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 213 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 214 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 218 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 219 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 220 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 221 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 222 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 223 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 224 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 225 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 226 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 227 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 228 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 229 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 230 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 233 Central Timer Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation Central Timer Module: Description and Operation System Description and Functional Operation For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2000 DN consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication (CCD Bus) of this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII (R) via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Central Locking Feature - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Remote Radio Switches - Remote Keyless Entry (RKE) - Vehicle Theft Security System (VTSS) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 236 The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for approximately six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Seat belt warning - Malfunction Indicator Lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) - Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini- trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all reset table conditions will be reset. This will occur only if a resettable function (AVG ECO, Trip Odometer, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 237 Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door key cylinder switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned on by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRBIII (R) under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRBIII (R), or customer programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features. The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate (DN) and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRBIII (R). The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the liftgate are equipped with key cylinder mux switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRBIII (R), or by using the customer programming sequence. Through the DRBIII (R), erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Speed Sensitive Intermittent Wipers The DN truck equipped with a highline CTM will utilize speed sensitive intermittent wipers. Only a highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Diagnostics Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 238 The CTM is fully addressable with the DRBIII (R) and it is the recommended method for diagnosis. The CTM reports up to 7 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII (R). The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 239 corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum for 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If the malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal - Logic Capacitor Low - AECM Output Driver Circuit Open - Firing Capacitor Low - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Shorted to Battery - Driver Squib Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Shorted to Battery - Passenger Squib Shorted to Ground - Warning Lamp Circuit Open/Shorted - No Cluster CCD Message - Cluster Message Mismatch Central Timer Module Diagnostic Trouble Codes Key Cylinder Lock Switch Failure/Lock - Door Lock Switch Failure - Door Unlock Switch Failure - Key Cylinder Lock Switch Failure/Unlock - Wiper Park Switch Failure - EEPROM Checksum Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 240 - Internal ROM Test Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 241 Central Timer Module: Description and Operation Central Timer Module For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 242 These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 245 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM-CHIME inoperative Chime Inoperative With Any Lamp or Gauge Warning Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 246 Test 1 - 3 SYMPTOM CHIME INOPERATIVE WITH ANY LAMP OR GAUGE WARNING POSSIBLE CAUSES - Open tone request signal circuit - Instrument cluster- chime inoperative with any warning lamp - CTM - Tone request signal circuit Chime Inoperative With Exterior Lights On and Drivers Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 247 Test 1 - 4 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LAMPS ON, DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-CHIME inoperative with headlamp switch - Headlamp switch key in ignition switch sense circuit open - Headlamp switch - key in ignition switch sense open Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 248 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 249 Test 4 - 8 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 250 - Key-in ignition switch sense circuit open Chime Remains On With Ignition On Test 1 - 3 SYMPTOM CHIME REMAINS ON WITH IGNITION ON POSSIBLE CAUSES - Instrument cluster-chime stays ON - Tone request circuit shorted ground - CTM-CHIME stays ON Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 251 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Key-in IGN switch sense circuit shorted ground - Shorted key-in switch - Headlamp switch shorted test, for chime system Doors Lock With Key In Ignition & Front Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 252 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 253 Test 4 - 8 SYMPTOM DOORS LOCK WITH KEY IN IGNITION & FRONT DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 254 - Key-in ignition switch sense circuit open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 255 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 256 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 257 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 258 Central Timer Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 259 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 260 Central Timer Module: Tools and Equipment DRBIII (R) (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 269 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 270 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 271 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 276 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 277 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 278 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 279 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 285 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 286 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: Customer Interest PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 291 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 292 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 298 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 299 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 300 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 305 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 306 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 307 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 308 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 313 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 314 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool > Page 319 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool > Page 320 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 326 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 327 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 332 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 333 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 339 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 340 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 341 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 346 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 347 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 348 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 349 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 350 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 3 - 5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 351 Powertrain Control Module: Locations Module Locations Powertrain Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 352 Fig. 29 - PCM Location And Mounting The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 355 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 356 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 357 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 359 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 360 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 361 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 363 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 366 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 370 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 373 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams 2000 Dodge JTEC System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description Powertrain Control Module: Description and Operation General Description POWERTRAIN CONTROL MODULE Fig. 1 - PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC (Jeep/Truck Engine Controller). The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto Shutdown (ASD) sense - Battery temperature - Battery voltage Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 380 - Ignition circuit sense (ignition switch in ON/OFF/CRANK/RUN position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. Sensor return is a low-noise, low-current, dedicated ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 381 Powertrain Control Module: Description and Operation PCM Operating Modes PCM OPERATING MODES As input signals to the PCM change, the PCM adjusts its response to 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. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. 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 air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch ON (Engine OFF) Mode When the ignition switch activates the fuel injection system, the following actions occur: 1. The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the ignition key is in the "ON" position and the engine is not running (0 rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Engine Start-up Mode This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive the camshaft and crankshaft signal within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequence. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode This is an open loop mode. The PCM adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. Cruise or Idle Mode When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Acceleration Mode Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 382 This is a closed loop mode. The PCM recognizes an increase in throttle position and a decrease in Manifold Vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Deceleration Mode This is a closed loop mode. The PCM recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Wide Open Throttle Mode This is an open mode. The Throttle Position Sensor notifies the PCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 383 Powertrain Control Module: Service and Repair Fig. 29 - PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 387 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 388 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 389 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 390 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 391 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 392 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Upstream and Downstream Relays are located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 396 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 397 Oxygen Sensor Relay: Diagrams Power Distribution Center Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 398 Oxygen Sensor Upstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 399 Oxygen Sensor Relay: Description and Operation OXYGEN SENSOR HEATER RELAYS - PCM OUTPUT The 2 oxygen (O2) sensor heater relays (upstream and downstream) are located in the Powertrain Distribution Center (PDC). Engines equipped with the California (NAE) Emissions Package use four O2 sensors. Two of the four sensor heater elements (upstream sensors 1/1 and 211) are controlled by the upstream heater relay through output signals from the Powertrain Control Module (PCM). The other two heater elements (downstream sensors 1/2 and 2/2) are controlled by the downstream heater relay through output signals from the PCM. To avoid a large simultaneous current surge, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 400 Oxygen Sensor Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The oxygen sensor heater relays are located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 405 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 406 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 407 Fuel Pump Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 408 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY - PCM OUTPUT The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 409 Fuel Pump Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 13). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 410 Fuel Pump Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 17). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 414 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 415 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 416 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 417 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 418 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 419 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM Mounting Screws 11.8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 424 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 425 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 426 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 427 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 428 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the center support bracket from the instrument panel. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 429 5. Do not reconnect the battery negative cable at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 434 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 435 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 436 Starter Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 437 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for starter relay identification and location. The starter relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil ill the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 438 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) 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 in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit to the park/neutral position switch is OK, refer to Park/Neutral Position Switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 439 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 446 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 447 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 451 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 452 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 453 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 458 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 459 Wiper Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 460 Wiper Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 461 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 462 Wiper Relay: Description and Operation The intermittent wipe 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 463 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. RELAY TEST Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Removal and Installation 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 Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 464 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Driver Door Arm/Disarm Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations Door Sensor/Switch (For Alarm): Locations The door ajar switch is integral to the door latch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 473 Door Sensor/Switch (For Alarm): Description and Operation The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 474 Door Sensor/Switch (For Alarm): Service and Repair The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation DOOR LOCK CYLINDER SWITCH The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are resistor multiplexed momentary switches that are hard wired between a body ground and the Central Timer Module (CTM) through the front door wire harnesses. These switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The door lock cylinder switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door lock cylinder switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the front door key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. LIFTGATE LOCK CYLINDER SWITCH The liftgate lock cylinder switch is mounted to the back of the liftgate key lock cylinder inside the liftgate. It is a resistor multiplexed momentary switch that is hard wired between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. This switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The liftgate lock cylinder switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate lock cylinder switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the liftgate key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test Lock Cylinder Switch: Testing and Inspection Door Lock Cylinder Switch Test 1. Disconnect the door lock cylinder switch wire harness connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Lock Cylinder Switch chart. 3. If a door lock cylinder switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test > Page 480 Lock Cylinder Switch: Testing and Inspection Liftgate Lock Cylinder Switch Test 1. Disconnect the liftgate lock cylinder switch wire harness connector from the liftgate wire harness connector. Liftgate Lock Cylinder Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Lift-gate Lock Cylinder Switch chart. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement > Page 483 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 492 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 498 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 499 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 500 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Remote Radio Switch Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 501 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remote Radio Switches Remote Radio Switch Test 1. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 502 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover, 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. 5. Install the driver side airbag module onto the steering wheel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 506 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 511 Power Door Lock Switch: Description and Operation The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 512 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity. See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off; Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the body half of the power lock switch wire Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 513 harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 514 Power Door Lock Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement.The heated mirror system will only operate when the ignition switch is in the ON position. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 518 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Control Knob Remove/Install - Typical 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut - Typical 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 519 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 523 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 524 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 525 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Black 2 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 534 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Wheel Speed Sensors/Tone Wheels Front Wheel Speed Sensors/Tone Wheels Front FRONT Wheel Speed Sensors/Tone Wheels Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 537 Wheel Speed Sensors/Tone Wheels Rear REAR Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 538 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Left Front Right Front Wheel Speed Sensor Connector Right Front Rear Wheel Speed Sensor Connector Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 539 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor LT Gray 2 Way Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor (Sensor Side) 2 Way Left Front Wheel Speed Sensor (Sensor Side) Rear Wheel Speed Sensor 2 Way Rear Wheel Speed Sensor Right Front Wheel Speed Sensor LT Gray 2 Way Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 540 Right Front Wheel Speed Sensor (Sensor Side) 2 Way Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, 4 Wheel Antilock Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 543 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System Wheel Speed Sensor: Service and Repair Rear Wheel Antilock Brake System REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Fig.9 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 546 Wheel Speed Sensor: Service and Repair Four Wheel Antilock Brake System Front Wheel Speed Sensor CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Wheel Speed Sensor REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 547 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 548 Wheel Speed Sensor: Service and Repair Tone Wheel Rear Wheel Antilock Brake System The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Front The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Refer to Transmission and Drivetrain, Drive axles, Bearings and Joints, Wheel Hub for the service procedure. Rear The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 556 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 557 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 558 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 559 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 560 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 565 Brake Switch (Cruise Control): Description and Operation The switch is mounted on the brake pedal mounting bracket under the instrument panel. Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged). The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal. With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low. The low voltage signal, monitored by the PCM, indicates that the brakes are not applied. When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on. Through the brake switch, current is routed to the speed control servo solenoids. The speed control solenoids (vacuum, vent and dump) are provided this current any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and current is interrupted to the solenoids. The normally open contacts are fed battery voltage. When the brakes are applied, battery voltage is supplied to the brake lamps. The Tail lamps on the Durango are mounted at the rear of the vehicle, outboard of the rear hatch and integrated into the lines of the vehicle. The tail lamp module contains a housing, lens, and three bulbs. Dual filament bulb is used for tail, stop, and turn signal operations. A separate bulb is used for back-up illumination. Tail lamp functions are controlled by the headlamp switch. Turn signal operations are controlled by the multifunction switch. Stop lamp functions are controlled by the stoplamp switch. The back-up lamps are controlled by the back-up lamp switch on the transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws 1.5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 569 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 570 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 571 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 572 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 573 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 584 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 585 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 5.6 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 590 Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 591 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient air temperature is monitored by the Compass Mini-Trip Computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a 5 volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Compass Mini-Trip Computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 592 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC,, (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilohms. At 55 °C (131 °F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 593 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation FRONT The heater-A/C blower mot9r is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. REAR The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an OFF position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 597 Blower Motor Switch: Testing and Inspection FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to 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 heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. REAR 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch 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 rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to 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 rear blower motor switch as you move the blower motor switch knob to each of the three 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 rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 598 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation ELECTRONIC CYCLING CLUTCH SWITCH The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9 °C (37.2 °F), and will close again when the refrigerant temperature reaches about 4.3 °C (39.7 °F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 602 Evaporator Temperature Sensor / Switch: Testing and Inspection Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C9OA circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 to 30 °C (68 to 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle ON and OFF two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: If the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 603 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is filled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations The high pressure cut-off switch is located on the discharge line near the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 608 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch, the low pressure cut-off switch, and the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 - 3375 kPa (450 - 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 - 2275 kPa (270 - 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 609 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the dual function high pressure switch, or the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure switch wire harness connector from the switch on the refrigerant system fitting. 3. On the dual function high pressure switch, check for continuity between terminals C and D. On the two terminal switch, check for continuity between both terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 610 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations The low pressure cut-off switch is located on the suction line jumper tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 614 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The low pressure cut-off switch is located on the suction line jumper tube. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The fitting is equipped with an O-ring to seal the switch connection. The low pressure cut-off switch is connected in series electrically with the high pressure cut-off switch, the heater-A/C controls, the Electronic Cycling Clutch Switch (ECCS), between ground, 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 refrigerant system pressure, ensuring a sufficient amount of refrigerant throughout the system. The low pressure cut-off switch contacts will open when the suction pressure is about 48 to 90 kPa (7 to 13 psi) or lower. The switch contacts will close when the suction pressure rises to about 103 to 193 kPa (15 to 28 psi) or above. Lower ambient temperatures, below about -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cut-off switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 615 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1 °C (30 °F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 48 to 193 kPa (15 to 28 psi) or above, and no continuity with a suction pressure reading of 90 kPa (13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 616 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 621 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 622 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 623 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 627 Fuel Gauge Sender: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 628 Fuel Gauge Sender: Description and Operation FUEL GAUGE SENDING UNIT Fig. 2 - Fuel Pump Module Components (Typical Pump Module Shown) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 629 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 630 Fuel Gauge Sender: Service and Repair Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 27). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 4-way electrical connector (Fig. 27). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 631 Fig. 28 - Fuel Gauge Sending Unit Lock Tab/Tracks 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 28). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 636 Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch Brake Light Switch: Description and Operation Base Brake System Stop Lamp Switch Refer to Brakes and Traction Control, Brakes, Description and Operation, Brake System Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch > Page 639 Brake Light Switch: Description and Operation RWAL System Brake Lamp Switch Refer to Brakes and Traction Control, Brakes, Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 640 Brake Light Switch: Testing and Inspection Refer to Brakes and Traction Control, Brakes, Testing and Inspection, Procedures, Base Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 641 Brake Light Switch: Service and Repair REMOVAL Fig. 15 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 645 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 646 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 647 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service Precautions Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service Precautions > Page 651 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 655 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 656 Hazard Warning Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multi-function switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning off), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning on), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 657 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 658 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 659 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 663 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 664 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The headlamp switch controls the parking lamps and the headlamps. A separate switch in the module controls the interior lamps, and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 665 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the headlamp switch from the instrument panel. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors.. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the OFF position, and continuity with the switch in the park or head lamps ON position. If OK, see Central Timer Module. If not OK, replace the faulty headlamp switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 666 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 670 Horn Switch: Description and Operation Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 671 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. If not OK, refer to Steering Column. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 672 Horn Switch: Service and Repair Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. See: Restraint Systems/Air Bag Systems/Air Bag Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 676 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 677 Turn Signal Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 678 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 679 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 680 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 686 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 687 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 688 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 689 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 693 Brake Pressure Switch: Description and Operation BRAKE SWITCH - PCM INPUT When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 698 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 699 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 700 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 701 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 707 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 708 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 709 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 710 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 711 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 715 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 716 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 717 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 718 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 719 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel level sensor (fuel gauge sending unit) is located on the fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 723 Fuel Pump Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 724 Fuel Level Sensor: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 725 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR - PCM INPUT The fuel level sensor (fuel gauge sending unit) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multiplexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multiplex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 726 Fuel Level Sensor: Testing and Inspection The fuel level sensor contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the level sensor only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air Temp. Sensor 28 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 730 Intake Air Temperature (IAT) Sensor: Locations Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The Intake Manifold Air Temperature (IAT) sensor is located in the front/side of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 731 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 732 Intake Air Temperature (IAT) Sensor: Description and Operation INTAKE MANIFOLD AIR TEMPERATURE SENSOR - PCM INPUT The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 733 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 737 Manifold Absolute Pressure (MAP) Sensor: Locations IAC/MAP/TPS Fig. 26 - MAP Sensor Location The MAP sensor is located on the front of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 738 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 739 Manifold Absolute Pressure (MAP) Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - PCM INPUT The Manifold Absolute Pressure (MAP) sensor is attached to the side of the engine throttle body with 2 screws. The sensor is connected to the throttle body with a rubber L-shaped fitting. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V For a pressure swing of 0 - 15 psi, the voltage changes 4.0 V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor ( TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 740 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 26 - MAP Sensor Location Fig. 27 - MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 741 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 745 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 746 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor 30 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 752 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions Oxygen Sensor: Diagrams California Emissions Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions > Page 755 Oxygen Sensor: Diagrams Federal Emissions Oxygen Sensor 1/1 Upstream (except California) Oxygen Sensor 1/2 Downstream (except California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 756 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 757 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 758 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S) - PCM INPUT The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. Non-California Engines On certain non-California (Federal) emissions packages, 2 sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Engines On certain California emissions packages, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. OXYGEN SENSOR OPERATION An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7 to 1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heaters/Heater Relays Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used. The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on these engines. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° F - 1100 °F (500 °C - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor (Certain Non-California Emissions) The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined Will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor (Certain Non-California Emissions) The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 759 Downstream Sensors (Certain California Emissions) Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 760 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 761 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 765 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 766 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 767 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 768 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 772 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 783 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 797 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE - PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Refer to Odometer and Trip Odometer in Instrument Panel for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 802 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 803 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 804 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 805 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 811 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 812 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 813 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 814 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 818 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 819 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 820 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 821 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 822 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 827 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 828 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 829 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 830 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 831 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 832 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 838 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.** Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 839 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 840 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 841 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 842 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 843 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 844 Passenger Airbag On/Off Switch - C1 (Switch Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The driver seat belt switch is integral to the driver seat belt retractor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 848 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 849 Seat Belt Buckle Switch: Description and Operation DRIVER SEAT BELT SWITCH The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half the switch opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 850 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 855 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 856 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 857 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 858 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 863 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 864 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 865 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 866 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 867 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 868 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair REMOVAL (1) Raise vehicle and position drain pan under switch. (2) Disconnect switch wires. (3) Remove switch from case. INSTALLATION Fig. 79 (1) Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case (Fig. 79). (2) Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. (3) Test continuity of new switch with 12V test lamp. (4) Connect switch wires and lower vehicle. (5) Top off transmission fluid level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 880 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 884 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 888 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 893 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned On. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 894 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch pod. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty rear window switch pod. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 895 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 899 Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 900 Power Window Switch: Description and Operation The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two- way power window switch mounted in a bezel on their respective door trim panels. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. The power window switch for the driver side front door has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 901 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, perform the diagnosis for Power Window System. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel. Unplug the wire harness connector from the switch unit, Power Window Switch Continuity - Driver Side Front - Quad Cab Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 902 Power Window Switch Continuity - Front and Rear Passenger Doors - Quad Cab 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, see Power Window Motor. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the ON position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 903 Power Window Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 908 Washer Fluid Level Switch: Description and Operation The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 909 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Washer Pump And Washer Fluid Level Sensor Remove/Install 2. Disconnect the headlamp and dash wire harness connector from the connector receptacle on the washer fluid level sensor. 3. Disconnect the washer supply hose from the outlet nipple of the front washer pump. Drain the washer fluid from the reservoir into a clean container for reuse. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal in the washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 913 Windshield Washer Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 914 Windshield Washer Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 915 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 916 Windshield Washer Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 917 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 918 Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 922 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 923 Wiper Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 924 Wiper Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 925 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 926 Wiper Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 927 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 928 Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications 2WD Caster (+- 0.50 Deg.) Preferred 3.10 deg Max Allowable R/L Diff erence 0.50 deg Camber (+- 0.50 Deg.) Preferred -0.25 deg Max Allowable R/L Diff erence 0.50 deg Total Toe (+- 0.06 Deg.) Preferred 0.10 deg Max Allowable R/L Diff erence 0.06 deg Thrus Angle (+- 0.40 Deg.) 0.00 deg 4WD Caster (+- 0.50 Deg.) Preferred 3.30 deg Max Allowable R/L Diff erence 0.50 deg Camber (+- 0.50 Deg.) Preferred -0.25 deg Max Allowable R/L Diff erence 0.50 deg Total Toe (+- 0.06 Deg.) Preferred 0.10 deg Max Allowable R/L Diff erence 0.06 deg Thrus Angle (+- 0.40 Deg.) 0.00 deg Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 933 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. Refer to Maintenance for the recommended maintenance schedule. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Part 1 Of 2 Part 2 Of 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 936 SUSPENSION AND STEERING SYSTEM DIAGNOSIS CHARTS Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 937 Alignment: Service and Repair Wheel Alignment Wheel Alignment Setup WHEEL ALIGNMENT NOTE: 4x4 suspension height measurement must be performed before alignment. CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. Camber Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. Caster Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. To increase positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. Toe Adjustment The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 938 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs. ). 5. Verify the specifications. 6. Turn off engine. Wheel Alignment Specifications Chart NOTE: All alignment specifications are in degrees. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 944 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). Fig. 33 - Air Cleaner Housing Assembly 2. Release housing cover from locating tabs on housing (Fig. 33) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 956 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 961 Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Cable Resistance Spark Plug Cable Resistance Minimum 250 ohms at 1 in 3000 ohms at 12 in Maximum 1000 ohms at 1 in 12000 ohms at 12 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 969 Ignition Cable: Service Precautions CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 970 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 971 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression~on. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 972 Ignition Cable: Service and Repair Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection - Internal - Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Type RC12LC4 Electrode Gap 1.01 mm Torque 35 - 41 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 983 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12LC4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 984 Spark Plug: Description and Operation All engines use resistor type spark plugs. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 985 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Normal Operating Normal Operation And Cold (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. On these engines, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 986 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. Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 987 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. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 988 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 989 Spark Plug: Service and Repair REMOVAL Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 1. Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 3. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 4. Inspect spark plug condition. Refer to Spark Plug Conditions. Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode fiat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Gap Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 990 Setting Spark Plug Gap-Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Cylinder Compression Pressure 689.5 kPa (100 psi) Maximum Variation Between Cylinders 25 % Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 994 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the third revolution. Continue the test for the remaining cylinders. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1001 Drive Belt: Service and Repair REMOVAL Fig. 57 Drive belts on 5.2L/5.9L engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. For more information, refer to Automatic Belt Tensioner-5.2L/5.9L Engine. 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1002 Fig. 58 CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to image for correct engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Refer to Automatic Belt Tensioner-5.2L/5.9L for more belt information. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark. Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/ width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. Refer to image. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). Fig. 33 - Air Cleaner Housing Assembly 2. Release housing cover from locating tabs on housing (Fig. 33) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1019 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1025 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Valve Body: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 1031 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Valve Body: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1036 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1037 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 1043 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1048 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1049 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1050 Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Filter - A/T: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1053 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1054 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1055 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1060 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair Fig. 26 - Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 26). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Locations Refrigerant Filter: Locations The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Locations > Page 1067 Refrigerant Filter: Description and Operation The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Locations > Page 1068 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Heating and Air Conditioning/Service and Repair Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. Remove the filter-drier from the engine compartment. INSTALLATION 1. Position the filter-drier and its bracket to the front fender wheelhouse front extension as a unit and loosely secure it with the mounting screw. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 4. Tighten the filter-drier bracket mounting screw to 6.8 Nm (60 in. lbs.). 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: "Service and Repair" See: Heating and Air Conditioning/Service and Repair 7. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 ml (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning Coolant Line/Hose: Service and Repair Without Air Conditioning REMOVAL 1. Partially drain cooling system. Refer to COOLING SYSTEM-DRAINING and FILLING. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 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). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. INSTALLATION 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1074 Coolant Line/Hose: Service and Repair With Air Conditioning REMOVAL If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. REFER TO REFRIGERANT WARNINGS IN HEATING AND AIR CONDITIONING. 1. Disconnect battery negative cable. 2. Partially drain cooling system. Refer to COOLING SYSTEM-DRAINING and FILLING. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1075 and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body control cables. Refer to ACCELERATOR PEDAL and THROTTLE CABLE in Powertrain Management for procedure. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts (number 1 and 2). 13. Remove six bracket bolts (number 3). 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3) to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Relax tension from belt tensioner. Install drive belt. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1076 CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. The correct belt with correct length must be used. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. Refer to Draining and Filling Cooling System. 16. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut- block style fittings. A stat-0 seal type flat steel gasket with a captured compressible O-ring, and spring lock coupler, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1082 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Front Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery Liquid Line Remove/Install 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. See Refrigerant Line Coupler for the procedures. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1083 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Rear Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1084 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction Line Jumper Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the rear liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suetion line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Suction and Discharge Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1085 Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1086 Hose/Line HVAC: Service and Repair B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt - suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1087 B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the lower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. 'Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Reinstall the lower B-pillar trim panel, upper trim panel, and seat belt bolt adjuster. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. See Refrigerant Line Coupler for the procedures. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1088 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Front Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1089 Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery Liquid Line Remove/Install 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. See Refrigerant Line Coupler for the procedures. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1090 Rear Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Suction Line Jumper Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1091 5. Remove the rear liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suetion line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Suction and Discharge Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1092 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1093 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt - suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the lower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. 'Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Reinstall the lower B-pillar trim panel, upper trim panel, and seat belt bolt adjuster. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. See Refrigerant Line Coupler for the procedures. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1094 11. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Refrigerant Hoses/Lines/Tubes Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system Will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry All tools and equipment must be designed for R-134a refrigerant. Underbody Refrigerant Line Replacement The underbody refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the underbody suction line and the underbody liquid line are available for separate service replacement, and may be removed from the vehicle independently for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1095 Underbody Refrigerant Line Remove/Install 3. From the engine compartment, disconnect the underbody liquid line refrigerant line coupler at the liquid line extension and the underbody suction line refrigerant line coupler at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Raise and support the vehicle. 5. From under the vehicle, disconnect the under-body liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screws that secure the three underbody refrigerant line clamps to the underbody. 7. Remove the underbody refrigerant line unit from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody refrigerant line unit to the underbody and secure the refrigerant line clamps with the mounting screws in three places. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings at the rear of the underbody liquid and suction lines and at the B-pillar liquid and suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 3. Lower the vehicle. 4. From the engine compartment, remove the tape or plugs from the refrigerant line fittings at the front of the underbody liquid and suction lines and at the liquid line extension and the suction line jumper. Connect the underbody refrigerant lines to the engine compartment refrigerant lines. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Lines to Rack Pressure Line 25 ft.lb Return Line 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1103 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1104 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. - Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1105 Brake Fluid: Service and Repair Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1110 Coolant: Fluid Type Specifications Use 50/50 mixture of ethylene-glycol antifreeze containing Alugard 340-2 and low mineral content water. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1111 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1116 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1117 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1118 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1119 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1120 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1121 Fluid - A/T: Technical Service Bulletins Transmission Fluid Level - Inspection Procedure NUMBER: 21-11-99 GROUP: Transmission DATE: Jul. 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-13-98, DATED OCT. 16, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO THE FLUID/FILTER REPLACEMENT PROCEDURE AND ADDING ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Transmission Fluid Level Inspection Procedure/Service Cautions MODELS: **2000 (AN) Dakota** **2000 (DN) Durango** 1999 - **2000** (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 45RFE TRANSMISSION. DISCUSSION: The 45RFE transmission, **newly introduced in the 1999 model year on Grand Cherokee models and for 2000 Dakota and Durango models, has some unique service features** compared with its predecessors. The following are some items to consider during service: Fluid Level Inspection 1. Warm the fluid to at least 21° C (70° F.) by operating the vehicle. 2. Measure the transmission fluid temperature using the DRB III(R). 3. Move the gear selector through drive and reverse. Place the gear selector in Park. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1122 4. Check the fluid level against the fluid level/temperature chart (Figure 1). NOTE: WHEN COLD (BELOW 10° C {50° F}) THE FLUID LEVEL WILL NOT REGISTER ON THE DIPSTICK. Fluid/Filter Replacement Accurate fluid level is difficult to determine cold. Initially add only 5 quarts of fluid during the refill procedure. **This amount will allow the engine to be started and the transmission to be operated in neutral until the transmission temperature has reached at least 21 C (70° F.)**. Once the fluid temperature is known, the final amount can be added without overfilling the transmission. Additionally, during this procedure, pressure switch and/or loss of prime DTC's may be set. If they are, erase them using the DRB Ill® before returning the vehicle to the customer. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Capacity Model 42RE, 44RE, 46RE ................................................................................................................... ............................................ 9.1-9.5Liters (19-20 Pt) Model 45RFE ....................................................................................................................................... ................................................. 13.33Liters (28.0 Pt) Capacities may vary. Check fluid level on dipstick according to applicable procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1125 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1126 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1129 Fluid - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1130 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1131 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 1136 Fluid - Differential: Technical Service Bulletins Differential - Fluid Discoloration Explanation NUMBER: 03-02-00 GROUP: Axles DATE: Mar.03, 2000 SUBJECT: 9.25 Axle Gear Marking Compound Causes A Milky-Like Appearance To The Axle Fluid MODELS: 1999 - 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 1999 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 9.25 INCH REAR AXLE AND BUILT BETWEEN NOV. 1, 1998 (MDH 1101XX) AND NOV. 1,1999 (MDH 1101XX). DISCUSSION: The customer or servicing technician may notice a milky-like appearance to the 9.25 inch rear axle fluid. This condition may be brought to the customer's attention when the axle fluid is inspected during normal service. Other than the concern for the color of axle fluid, the customer does not experience any other axle complaint. The customer or servicing technician may be concerned because a milky-like appearance to the axle fluid may also indicate the presence of water. The cause of the milky-like appearance to the axle fluid may be due to the use of a white color gear marking compound during the axle assembly process. Axle gear marking compound is used to verify correct ring and pinion gear alignment during manufacture. The 9.25 inch rear axle is assembled on two different assembly lines. To visually distinguish axles from each assembly line, one assembly line used a white color gear marking compound (versus yellow). Half of the axles that were assembled during the above time frame may have the white gear marking compound mixed with the rear axle fluid. The white color gear marking compound is no longer in use by the axle assembly plant. NOTE: IF THE MILKY-LIKE REAR AXLE FLUID APPEARANCE IS DUE TO THE WHITE GEAR MARKING COMPOUND, THEN NO SERVICE ACTION IS NECESSARY TO ADDRESS THIS CONDITION. If the milky-like rear axle fluid appearance is due to the presence of water, then the rear axle will require service. Axle fluid, contaminated with water, may cause rust and damage to the internal components of the axle. Any water in the axle fluid will begin to boil off (reach its gaseous state) before the oil. Placing a small sample of axle fluid on a hot steel surface (around 100C or 212F) will cause any water that may be present in the fluid to boil off with a "sizzle-like" sound. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID CAPACITY C205F .................................................................................................................................................. .................................................... 1.66Liters (3.5 pts) 8 1/4 AA ............................................................................................................................................... ................................................... 2.22Liters (4.7 pts) With Trac-Lok include 5.0 oz of friction modifier 9 1/4 ..................................................................................................................................................... .................................................... 2.32Liters (4.9 pts) With Trac-Lok include 5.0 oz of friction modifier Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1139 Fluid - Differential: Fluid Type Specifications Rear Differential 8 1/4" ................................................................................................................................................... ......................................... Thermally Stable 80W-90 9 1/4" ................................................................ ............................................................................................................................ Thermally Stable 75W-90 Note: Vehicles equipped with Trac-Lok limited slip differential requires use of friction modifier. Front Differential Thermally Stable 80W-90. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1140 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Description and Operation > Rear Axle - 8 1/4 Fluid - Differential: Description and Operation Rear Axle - 8 1/4 DESCRIPTION Multi-purpose, hypoid gear lubricant should be used for rear axles with a standard differential. The lubricant should have a MIL-L-2105C and API GL 5 quality specifications. Trac-Lok differentials require the addition of 5 oz. of friction modifier to the axle lubricant after service. The 8 1/4 axle lubricant capacity is 2.22 L (4.7 pts.) total, including the friction modifier, if necessary. The 9 1/4 axle lubricant capacity is 2.32 L (4.9 pts.) total, including friction modifier, if necessary. NOTE: If the rear axle is submerged in water, the lubricant must be replaced immediately. Avoid the possibility of premature axle failure resulting from water contamination of the lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Description and Operation > Rear Axle - 8 1/4 > Page 1143 Fluid - Differential: Description and Operation Rear Axle - 9 1/4 DESCRIPTION Multi-purpose, hypoid gear lubricant should be used for rear axles with a standard differential. The lubricant should have a MIL-L-2105C and API GL 5 quality specifications. Trac-Lok differentials require the addition of 5 oz. of friction modifier to the axle lubricant after service. The 8 1/4 axle lubricant capacity is 2.22 L (4.7 pts.) total, including the friction modifier, if necessary. The 9 1/4 axle lubricant capacity is 2.32 L (4.9 pts.) total, including friction modifier, if necessary. NOTE: If the rear axle is submerged in water, the lubricant must be replaced immediately. Avoid the possibility of premature axle failure resulting from water contamination of the lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Description and Operation > Page 1144 Fluid - Differential: Service and Repair (1) Raise and support the vehicle. (2) Remove the lubricant fill hole plug from the differential housing cover. (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning. (5) Remove the original sealant from the housing and cover surfaces. Fig. 9 (6) Apply a bead of Mopar(r) Silicone Rubber Sealant, or equivalent, to the housing cover (Fig. 9). Install the housing cover within 5 minutes after applying the sealant. (7) Install the cover and any identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. (8) For Trac-lok (r) differentials, a quantity of Mopar(r) Trac-lok(r) lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. Refer to the Specifications for the quantity necessary. (9) Fill differential with Mopar(r) Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. Refer to Specifications for the quantity necessary. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. (10) Install the fill hole plug and lower the vehicle. (11) Trac-lok(r) differential equipped vehicles should be road tested by making 10 to 12 slow figure eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ .............................................................. 5.0 Qt (US) Engine Oil without Filter ....................................................................................................................... .............................................................. 4.5 Qt (US) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1149 Engine Oil: Fluid Type Specifications Engine Oil Type Above 0°F (-18°C) ............................................................................................................................... ................................................. 10W-30 (Preferred) Below 32°F (0°C) ............................................... ....................................................................................................................................................... 5W-30 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1150 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1155 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1156 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1157 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1158 Power Steering Fluid: Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1159 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant Single Unit ......................................................................................................................................................... 0.793 kilograms (28 oz.) R134a Refrigerant Dual Unit ........................................................................................................................................................... 0.907 kilograms (32 oz.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1164 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1165 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1166 http://www.macsw.org/ Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Front .................................................................................................................................................... ...................................................... 180 ml (6.1 oz.) Front & Rear ....................................................... .......................................................................................................................................... 240 ml (8 oz.) Filter-Drier ............................................................................................................................................ ............................................................. 30 ml (1 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator Front .................................................................................................................................................... ........................................................... 60 ml (2 oz.) Rear .................................................................... ............................................................................................................................................ 30 ml (1 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1171 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type SP-20 PAG Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1172 Refrigerant Oil: Service and Repair When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 ml (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when a filter-drier, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding OVERVIEW A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. BLEEDING PROCEDURE 1. Mount master cylinder in vise. Master Cylinder Bleeding - Typical 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir. 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1177 Brake Bleeding: Service and Repair Base Brake System BASE BRAKE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1178 Brake Bleeding: Service and Repair Antilock Brake System Four Wheel ABS Brake System ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. Refer to Brakes, Brake Bleeding, Service and Repairs, Service Procedures for procedure. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Rear Wheel Antilock Brake Bleeding OVERVIEW Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1179 PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use the adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1183 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Junction Block > Page 1189 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1192 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1193 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1194 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1195 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1196 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1197 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1198 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1199 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1200 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1201 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1202 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1203 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Junction Block > Page 1204 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Junction Block > Page 1207 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Page 1208 Fuse: Description and Operation GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is used on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Page 1209 Fuse: Service and Repair Generator Cartridge Fuse If a generator cartridge fuse fails, be certain to inspect and test the vehicle charging system before replacing the cartridge fuse and returning the vehicle to service. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unlatch and remove the cover from the Power Distribution Center (PDC). 3. Remove the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. 4. Remove the generator cartridge fuse from the PDC. INSTALLATION 1. Position the generator cartridge fuse onto the two B(+) terminal stud bus bars within the PDC. 2. Install and tighten the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. Tighten the screws to 3.4 Nm (30 in. lbs.). Be certain that both screws are tightened to the proper torque value. 3. Install and latch the cover onto the PDC. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Junction Block > Page 1214 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 8w-12-4 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Fuse Block: Electrical Diagrams 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 8w-12-3 Fuse/Relay Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 8w-11-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 8w-11-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 8w-11-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 8w-11-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1270 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Junction Block > Page 1273 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1274 Fuse Block: Description and Operation JUNCTION BLOCK Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged; the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. RELAY AND FUSE BLOCK Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1275 Relay And Fuse Block Location The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel. The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block Fuse Block: Service and Repair Fuse/Relay Block The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Relay and Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 1278 Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles. 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 1279 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block > Page 1284 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1287 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1288 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1289 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1290 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1291 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1292 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1293 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1294 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1295 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1296 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1297 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1298 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1299 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block > Page 1302 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Application and ID Maintenance Required Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Maintenance Required ........................................................................................................................ ..................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine ...................................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 1313 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications Tire Size Manufacturer Revolutions Per Mile P235/75R15 XL MICHELIN 720 P235/75R15 XL GOODYEAR 729 P275/60R17 GOODYEAR 697 31x10.50R15 LT GOODYEAR 689 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire Tires: Description and Operation Tire DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown in Tire Rotation. This will help to achieve a greater tread life. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1320 Tires: Description and Operation Radial-Ply Tire DESCRIPTION Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 50 MPH is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1321 Tires: Description and Operation Replacement Tires DESCRIPTION The original equipment tires provide a proper balance of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1322 Tires: Description and Operation Tire Inflation Pressures DESCRIPTION Fig. 4 Under inflation will cause rapid shoulder wear, tire flexing, and Possible tire failure. Fig. 5 Over inflation will cause rapid center wear and loss of the tire's ability to cushion shocks. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the Tire Inflation Pressure Chart provided with the vehicles Owners Manual. A Certification Label on the drivers side door pillar provides the minimum tire and rim size for the vehicle. The label also list the cold inflation pressure for these tires at full load operation. Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure should be checked cold once a month. Tire pressure decreases as the ambient temperature drops. Check tire pressure frequently when ambient temperature varies widely. Tire inflation pressures are cold inflation pressure. The vehicle must sit for at least 3 hours to obtain the correct cold inflation pressure reading, or be driven less than one mile after sitting for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1323 Tires: Description and Operation Tire DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown in Tire Rotation. This will help to achieve a greater tread life. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Radial-Ply Tire Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1324 DESCRIPTION Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 50 MPH is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Replacement Tires DESCRIPTION The original equipment tires provide a proper balance of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. Tire Inflation Pressures DESCRIPTION Fig. 4 Under inflation will cause rapid shoulder wear, tire flexing, and Possible tire failure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 1325 Fig. 5 Over inflation will cause rapid center wear and loss of the tire's ability to cushion shocks. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the Tire Inflation Pressure Chart provided with the vehicles Owners Manual. A Certification Label on the drivers side door pillar provides the minimum tire and rim size for the vehicle. The label also list the cold inflation pressure for these tires at full load operation. Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure should be checked cold once a month. Tire pressure decreases as the ambient temperature drops. Check tire pressure frequently when ambient temperature varies widely. Tire inflation pressures are cold inflation pressure. The vehicle must sit for at least 3 hours to obtain the correct cold inflation pressure reading, or be driven less than one mile after sitting for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Tire Pressure-High Speed Operation DESCRIPTION Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. For speeds up to and including 120 km/h (75 mph), tires must be inflated to the pressures shown on the tire placard. For continuous speeds in excess of 120 km/h (75 mph), tires must be inflated to the maximum pressure specified on the tire sidewall. Vehicles loaded to the maximum capacity should not be driven at continuous speeds above 75 mph (120 km/h). For emergency vehicles that are driven at speeds over 90 mph (144 km/h), special high speed tires must be used. Consult tire manufacturer for correct inflation pressure recommendations. Spare Tire - Temporary DESCRIPTION The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 MPH when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators Tires: Testing and Inspection Tread Wear Indicators Fig. 2 Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 1328 Tires: Testing and Inspection Tread Wear Patterns Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Pressure Gauges A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1331 Tires: Removal and Replacement Fig. 7 For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area. The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 1335 Wheels: Testing and Inspection Inspect wheels for: Excessive runout - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1340 Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Wheel Hub, Service and Repair for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1343 Wheel Bearing: Service and Repair Rear For further information regarding this component and the system it is a part of, refer to Axle Shaft, Conventional Fixed/Floating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1352 Wheel Fastener: Specifications Torque Specifications CAUTION: DO NOT USE CHROME PLATED LUG NUTS WITH CHROME PLATED WHEELS. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1353 Wheel Fastener: Service and Repair CAUTION: Do not use a hammer to remove wheel studs. REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, caliper adapter and rotor, Refer to Brakes and Traction Control for procedure. Fig. 9 4. Remove stud from hub with Remover C-4150A. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor, caliper adapter. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Cylinder Compression Pressure 689.5 kPa (100 psi) Maximum Variation Between Cylinders 25 % Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1359 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the third revolution. Continue the test for the remaining cylinders. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Diameter Number 1 ............................................................................................................................................. ................................................ 2.000 - 2.001 inch Number 2 .............................................................. ............................................................................................................................... 1.984 - 1.985 inch Number 3 ............................................................................................................................................. ................................................ 1.969 - 1.970 inch Number 4 .............................................................. ............................................................................................................................... 1.953 - 1.954 inch Number 5 ............................................................................................................................................. ............................................ 1.5625 - 1.5635 inch Camshaft Bearing Journal Diameter Number 1 ............................................................................................................................................. ................................................ 1.997 - 1.999 inch Number 1 .............................................................. ............................................................................................................................... 1.981 - 1.983 inch Number 1 ............................................................................................................................................. ................................................ 1.966 - 1.968 inch Number 1 .............................................................. ............................................................................................................................... 1.950 - 1.952 inch Number 1 ............................................................................................................................................. ............................................ 1.5595 - 1.5615 inch Camshaft Bearing to Journal Clearance Standard .............................................................................................................................................. ................................................. 0.001 - 0.003 inch Service Limit ........................................................ ............................................................................................................................................ 0.005 inch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Service and Repair > Procedures Camshaft Bearing: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Service and Repair > Procedures > Page 1366 Camshaft Bearing: Removal and Replacement REMOVAL NOTE: This procedure requires that the engine is removed from the vehicle. 1. With engine completely disassembled, drive out rear cam bearing core plug. Fig. 62 2. Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer Tool C-3132-A) at back of each bearing shell. Drive out bearing shells (Fig. 62). INSTALLATION 1. Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 50 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Procedures Camshaft Gear/Sprocket: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Camshaft Thrust Plate Bolts 210 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bearing Diameter No. 1 2.000 - 2.001 in No. 2 1.984 - 1.985 in No. 3 1.969 - 1.970 in No. 4 1.953 - 1.954 in No. 5 1.5625 - 1.5635 in Bearing Journal Diameter No. 1 1.998 - 1.999 in No. 2 1.982 - 1.983 in No. 3 1.967 - 1.968 in No. 4 1.951 - 1.952 in No. 5 1.5605 - 1.5615 in Bearing to Journal Clearance Standard 0.001 - 0.003 in Service Limit 0.005 in End Play 0.002 - 0.010 in Valve Timing Exhaust Valve Closes 33 deg ATDC Opens 56 deg BBDC Duration 269 deg Intake Valve Closes 62 deg ATDC Opens 7 deg BBDC Duration 249 deg Valve Overlap 41 deg Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1380 Camshaft: Removal and Replacement Fig. 58 NOTE: The camshaft has an integral oil pump and distributor drive gear (Fig. 58). REMOVAL 1. Remove the radiator. Refer to Cooling for the correct procedures. 2. Remove the A/C Condenser (if equipped). 3. Remove the engine cover. 4. Remove intake manifold. 5. Remove cylinder head covers. 6. Remove timing case cover and timing chain. 7. Remove rocker arms. 8. Remove push rods and tappets. Identify each part so it can be installed in its original location. 9. Remove distributor and lift out the oil pump and distributor drive shaft. Fig. 59 10. Remove camshaft thrust plate, note location of oil tab (Fig. 59). 11. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1381 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. Fig. 60 2. Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear (Fig. 60). 3. Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the Welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. 4. Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 Nm (210 in. lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. 5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 6. Place timing chain around both sprockets. 7. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 8. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Fig. 61 9. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks (Fig. 61). 10. Install the camshaft bolt/cup washer. Tighten bolt to 68 Nm (50 ft. lbs.) torque. 11. Measure camshaft end play. Refer to Specifications for proper clearance. If not within limits install a new thrust plate. 12. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. 13. Install distributor and distributor drive shaft. 14. Install push rods and tappets. 15. Install rocker arms. 16. Install timing case cover. 17. Install cylinder head covers. 18. Install intake manifold. 19. Install the engine cover. 20. Install the A/C Condenser (if equipped) 21. Install the radiator. Refer to Cooling for the correct procedures. 22. Refill cooling system. 23. Start engine check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Hydraulic Tappets Body Diameter 0.9035 - 0.9040 in Clearance (To Bore) 0.0011 - 0.0024 in Dry Lash 0.060 - 0.210 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Additional Information Lifter / Lash Adjuster: Service and Repair Additional Information Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Additional Information > Page 1387 Lifter / Lash Adjuster: Service and Repair Removal and Installation REMOVAL 1. Remove the air cleaner assembly and air inlet hose. 2. Remove cylinder head cover, rocker assembly and push rods. Identify push rods to ensure installation in original location. 3. Remove intake manifold, yoke retainer and aligning yokes. 4. Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet. 5. Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. INSTALLATION 1. If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet. 2. Lubricate tappets. 3. Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). 4. Install aligning yokes with ARROW toward camshaft. 5. Install yoke retainer. Tighten the bolts to 23 Nm (200 in. lbs.) torque. Install intake manifold. 6. Install push rods in original positions. 7. Install rocker arm. 8. Install cylinder head cover. 9. Install air cleaner assembly and air inlet hose. 10. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Push Rod Length 6.915 - 6.935 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications > Page 1391 Push Rod: Service and Repair REMOVAL 1. Remove cylinder head cover and gasket. Fig. 49 2. Remove the rocker arm bolts and pivots (Fig. 49). Place them on a bench in the same order as removed. 3. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1395 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove cylinder head cover and gasket. Fig. 49 2. Remove the rocker arm bolts and pivots (Fig. 49). Place them on a bench in the same order as removed. 3. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Rod Journal Diameter .......................................................................................................................... .................................................... 2.124 - 2.125 inch Out of Round (Max.) ......................................... ................................................................................................................................................... 0.001 inch Taper (Max.) ................................................................................................................................ ........................................................................ 0.001 inch Bearing Clearance .................................... ........................................................................................................................................... 0.0005 0.0022 inch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1400 Connecting Rod Bearing: Service and Repair Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Connecting Rods Piston Pin Bore Diameter 0.9829 - 0.9834 in Side Clearance 0.006 - 0.014 in Journal Diameter 2.124 - 2.125 in Out of Round (Max) 0.001 inch Taper (Max) 0.001 inch Bearing Clearance 0.0005 - 0.0022 in Connecting Rod Cap Bolts 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 1405 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts .................................................................................................................. .................................................... 61 Nm (45 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1408 Connecting Rod: Removal and Replacement REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. Fig. 70 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 70). 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Additional Information Crankshaft Gear/Sprocket: Service and Repair Additional Information Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Main Bearing Journal Diameter 2.8095 - 2.8105 in Out of Round (Max.) 0.001 in Bearing Clearance Journal #1 0.0005 - 0.0015 in Journals # 2 - 5 0.0005 - 0.002 in Service Limit Journal #1 0.0015 in Journals #2-5 0.0025 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 1417 Crankshaft Main Bearing: Specifications Torque Torque Main Bearing Cap Bolts 115 Nm (85 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures Crankshaft Main Bearing: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 1420 Crankshaft Main Bearing: Removal and Replacement REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Identify bearing caps before removal. Remove bearing caps one at a time. Fig. 67 4. Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft. 5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing Shell. INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing capbolts removed during service procedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059. 3. Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 Nm (85 ft. lbs.) torque. 4. Install the oil pump. 5. Install the oil pan. 6. Start engine check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Rod Journal Diameter 2.124 - 2.125 in Out-of-Round (Max.) 0.0001 in Taper (Max.) 0.0001 in Bearing Clearance 0.0005 - 0.0022 in Main Bearing Journal Diameter 2.8095 - 2.8105 in Out-of-Round (Max.) 0.001 in Taper (Max.) 0.001 in Bearing Clearance #1 Journal 0.0005 - 0.0015 in #2-5 Journals 0.0005 - 0.002 in Service Limit #1 Journal 0.0015 in #2-5 Journals 0.0025 in End Play 0.002 - 0.007 in Service Limit 0.010 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1426 Crankshaft: Removal and Replacement Fig. 71 A crankshaft which has undersized journals will be stamped with 1/4 inch letters on the milled flat on the No.3 crankshaft counterweight (Fig. 71). FOR EXAMPLE: R2 stamped on the No.3 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 inch) undersized. M4 indicates that the No.4 main journal is 0.025 mm (0.001 inch) undersized. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 inch) undersized. CRANKSHAFT IDENTIFICATION MARK LOCATION CHART When a crankshaft is replaced, all main and connecting rod bearings should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the vibration damper. 4. Remove the timing chain cover. 5. Identify bearing caps before removal. Remove bearing caps and bearings one at a time. 6. Lift the crankshaft out of the block. 7. Remove and discard the crankshaft rear oil seals. 8. Remove and discard the front crankshaft oil seal. INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages. CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. CLEANING Clean Loctite 518 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of rear cap. INSTALLATION 1. Lightly oil the new upper seal lips with engine oil. 2. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1427 3. Position the crankshaft into the cylinder block. 4. Lightly oil the new lower seal lips with engine oil. 5. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Fig. 72 6. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap (Fig. 72). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 7. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 8. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. Fig. 73 9. Install oil pump. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 73). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Install new front crankshaft oil seal. 11. Immediately install the oil pan. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block Heater Bolt 17 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1431 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Drain coolant from radiator and cylinder block. Refer to Draining Cooling System. Fig. 55 3. Remove power cord from block heater. 4. Loosen screw at center of block heater. Remove heater assembly and O-ring seal. INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. (all except 4.7L Engine). Position O-ring seal on heater then insert block heater assembly with element loop pointing down. Fig. 56 3. 4.7L Engine Only, Insert block heater assembly with element loop pointing upward (12 O'clock). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1432 4. With block heater fully seated, tighten center screw to 2 Nm (17 in. lbs.) torque. 5. Fill cooling system with recommended coolant. Refer to Filling Cooling System. 6. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair Fig. 79 Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate (Fig. 79). This will reduce internal leakage and help maintain higher oil pressure at idle. REMOVAL Fig. 80 1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug (Fig. 80). 2. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. INSTALLATION Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Be certain the new plug is cleaned of all oil or grease. 1. Coat edges of plug and core hole with Mopar Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting, as restricted coolant flow can result and cause serious engine problems. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 1436 2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. 3. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Pulley Bolts 210 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1440 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the cooling system fan. 3. Remove the cooling fan shroud. 4. Remove the accessory drive belt. 5. Remove vibration damper bolt and washer from end of crankshaft. 6. Position Special Tool 8513 Insert into the crankshaft nose. Fig. 51 7. Install Special Tool 1026 Three Jaw Puller onto the vibration damper (Fig. 51). 8. Pull vibration damper off of the crankshaft. INSTALLATION CAUTION: Thoroughly remove any contaminants from the crankshaft nose and the vibration damper bore. Failure to do so can cause sever damage to the crankshaft. 1. Position the vibration damper onto the crankshaft. Fig. 52 2. Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 52). 3. Install the crankshaft bolt and washer. Tighten the bolt to 244 Nm (180 ft. lbs.) torque. 4. Install the accessory drive belt. 5. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95 in. lbs.) torque. 6. Install the cooling fan. 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance at Top of Skirt Minimum 0.0005 in Maximum 0.0015 in Land Clearance (Diameter) Minimum 0.020 inch Maximum 0.026 inch Piston Length 3.19 inch Ring Groove Depth #1 & 2 Minimum 0.187 inch Maximum 0.193 inch Ring Groove Depth #3 Minimum 0.157 inch Maximum 0.164 inch Weight Minimum 20.53 oz (US) Maximum 20.67 oz (US) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1446 Piston: Removal and Replacement REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. Fig. 70 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 70). 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston 0.000253- 0.00074 in Diameter 0.9845 - 0.9848 in End Play None Length 2.67 - 2.69 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1450 Piston Pin: Service and Repair Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring Gap Top Compression Ring Minimum 0.012 in Maximum 0.022 in 2nd Compression Ring Minimum 0.022 in Maximum 0.031 in Oil Control (Steel Rails) Minimum 0.015 in Maximum 0.055 in Ring Side Clearance Compression Rings Minimum 0.0016 in Maximum 0.0033 in Oil Control (Steel Rails) Maximum 0.002 in Maximum 0.008 in Ring Width Compression Rings Minimum 0.060 in Maximum 0.061 in Oil Control (Steel Rails) Minimum 0.018 in Maximum 0.019 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1454 Piston Ring: Service and Repair Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1462 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1466 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove cylinder head cover and gasket. Fig. 49 2. Remove the rocker arm bolts and pivots (Fig. 49). Place them on a bench in the same order as removed. 3. Remove the push rods and place them on a bench in the same order as removed. INSTALLATION 1. Rotate the crankshaft until the "V8" mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). 4. Install cylinder head cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 95 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1470 Valve Cover: Service and Repair Fig. 48 A steel backed silicon gasket is used with the cylinder head cover (Fig. 48). This gasket can be used again. REMOVAL 1. Disconnect the negative cable from the battery. 2. Disconnect closed ventilation system and evaporation control system from cylinder head cover. 3. Remove the air inlet hose. 4. Remove cylinder head cover and gasket. The gasket may be used again. INSTALLATION 1. The cylinder head cover gasket can be used again. Install the gasket onto the head rail. 2. Position the cylinder head cover onto the gasket. Tighten the bolts to 11 Nm (95 in. lbs.) torque. 3. Install closed crankcase ventilation system and evaporation control system. 4. Install the air inlet hose. 5. Connect the negative cable to the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle 44.25 - 44.75 deg Runout (Max.) 0.003 in Width Intake 0.040 - 0.060 in Exhaust 0.060 - 0.080 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs Free Length 1.967 in Spring Tension Valve Closed 85 lbf at 1.64 in Valve Open 200 lbf at 1.212 in Number of Coils 6.8 Installed Height 1.64 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Additional Information Valve Spring: Service and Repair Additional Information Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Additional Information > Page 1479 Valve Spring: Service and Repair Valve Spring and Stem Seal Replacement 1. Remove the air cleaner. 2. Remove cylinder head covers and spark plugs. 3. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 4. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at TDC on the compression stroke. 5. Remove rocker arms. 6. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620 - 689 kPa (90 - 100 psi) air pressure. 7. Using Valve Spring Compressor Tool MD-998772A with adapter 6716A, compress valve spring and remove retainer valve locks and valve spring. 8. Install seals on the exhaust valve stem and position down against valve guides. 9. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 10. Follow the same procedure on the remaining 7 cylinders using the firing sequence 1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 11. Remove adapter from the No.1 spark plug hole and install spark plugs. 12. Install rocker arms. 13. Install covers and coil wire to distributor. 14. Install air cleaner. 15. Road test vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Additional Information > Page 1480 Valve Spring: Service and Repair Off Vehicle Service REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool MD-998772A. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle 43.25 - 43.75 deg Head Diameter Intake 1.88 in Exhaust 1.617 in Length (Overall) Intake 4.969 - 4.994 in Exhaust 4.978 - 5.012 in Lift (@ zero lash) Intake 0.410 in Lift (@ zero lash) Exhaust 0.417 in Stem Diameter Intake 0.372 - 0.373 in Exhaust 0.371 - 0.372 in Stem to Guide Clearance Intake 0.001 - 0.003 in Exhaust 0.002 - 0.004 in Service Limit (Rocking Method) 0.017 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1484 Valve: Testing and Inspection Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1485 Valve: Service and Repair REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool MD-998772A. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1490 Drive Belt: Service and Repair REMOVAL Fig. 57 Drive belts on 5.2L/5.9L engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. For more information, refer to Automatic Belt Tensioner-5.2L/5.9L Engine. 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1491 Fig. 58 CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to image for correct engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Refer to Automatic Belt Tensioner-5.2L/5.9L for more belt information. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark. Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/ width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. Refer to image. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Automatic Belt Tensioner to Mounting Bracket 50 ft.lb Automatic Belt Tensioner Pulley Bolt 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1495 Drive Belt Tensioner: Service and Repair REMOVAL 1. Remove accessory drive belt. 2. Disconnect wiring and secondary cable from ignition coil. Fig. 61 3. Remove two mounting bolts and ignition coil from engine (Fig. 61). 4. Remove mounting bolt and tensioner assembly from engine. WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY (EXCEPT FOR PULLEY). 5. Remove pulley bolt. Remove pulley from tensioner. INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). 2. Position tensioner assembly and install mounting screw tighten screw to 67 Nm (50 ft. lbs.). 3. Connect all wiring to ignition coil. 4. Position coil to tensioner assembly, install two mounting screws. Tighten to 11 Nm (100 in. lbs.). CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. 5. Install accessory drive belt. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Generator/Compressor Mounting Bracket Bolts #1 and 2 40 ft.lb #3 30 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates Engine Mount: Technical Service Bulletins Engine/Electrical - Torque Spec/Schematic Updates NUMBER: 26-02-00D GROUP: Miscellaneous DATE: April, 2000 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 2000 Durango Service Manual - Publication Number 81-370-0016 DESCRIPTION OF CHANGES Updates to the wiring schematic Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1503 8W-30-25 Updates to the engine support & crossmember torque specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1504 9-29 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1505 9-81 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1506 9-102 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1507 9-132 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1508 9-160 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1509 9-161 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 1510 1-189 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1511 Engine Mount: Specifications Front Insulator Through Bolt/Nut 70 ft.lb Front Insulator to Support Bracket Through Bolt/Nut 75 ft.lb Front Insulator to Block Bolts 70 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1512 Engine Mount: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise hood and position fan to assure clearance for radiator top tank and hose. CAUTION: DO NOT lift the engine by the intake manifold. 3. Install engine lifting fixture. 4. Raise vehicle on hoist. Fig. 32 Fig. 33 5. Remove the insulator through bolt (Fig. 32) (Fig. 33). 6. Raise engine with lifting fixture SLIGHTLY. Remove insulator retaining bolts and remove the insulator assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1513 7. Remove insulator heat shield and transfer to new insulator. INSTALLATION 1. With the engine raised SLIGHTLY, position insulator assembly onto the engine block and install bolts. Tighten the bolts to 41 Nm (30 ft. lbs.) torque. Fig. 34 2. Lower engine with lifting fixture while guiding insulator assembly into the engine insulator bracket (Fig. 34). 3. Install insulator to bracket thru-bolt. Tighten the thru-bolt nut to 68 Nm (50 ft. lbs.) torque. 4. Remove lifting fixture. 5. Connect the negative cable to the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Idler Pulley Bolt 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 6 psi (at normal operating temperature) CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 30 - 80 psi BYPASS RELIEF VALVE SETTING 9 - 15 psi OIL PRESSURE SWITCH ACTUATING PRESSURE 5 - 7 psi Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ .............................................................. 5.0 Qt (US) Engine Oil without Filter ....................................................................................................................... .............................................................. 4.5 Qt (US) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1528 Engine Oil: Fluid Type Specifications Engine Oil Type Above 0°F (-18°C) ............................................................................................................................... ................................................. 10W-30 (Preferred) Below 32°F (0°C) ............................................... ....................................................................................................................................................... 5W-30 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1529 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 215 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1533 Oil Pan: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove engine oil dipstick. 3. Disconnect distributor cap and position away from cowl. 4. Raise vehicle. 5. Drain engine oil. 6. Remove exhaust pipe. 7. Remove engine mount insulator through bolts. 8. Raise engine by way of oil pan using a block of wood between the jack and oil pan. 9. When engine is high enough, place mount through bolts in the engine mount attaching points on the frame brackets. 10. Lower engine so bottom of engine mounts rest on the replacement bolts placed in the engine mount frame brackets. 11. Remove oil pan and one-piece gasket. INSTALLATION Fig. 68 1. Fabricate 4 alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 68). Fig. 69 2. Install the dowels in the cylinder block (Fig. 69). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1534 3. Apply small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. 4. Slide the one-piece gasket over the dowels and onto the block. 5. Position the oil pan over the dowels and onto the gasket. 6. Install the oil pan bolts. Tighten the bolts to 24 Nm (215 in. lbs.) torque. 7. Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 Nm (215 in. lbs.) torque. 8. Install the drain plug. Tighten drain plug to 34 Nm (25 ft. lbs.) torque. 9. Raise engine by way of oil pan with a wood block placed between jack and oil pan. 10. Remove temporary bolts from frame brackets and lower engine. Install mount insulator through bolts and tighten to 95 Nm (70 ft. lbs.). 11. Install exhaust pipe. 12. Lower vehicle. 13. Connect the distributor cap. 14. Install dipstick. 15. Connect the negative cable to the battery. 16. Fill crankcase with oil to proper level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1541 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 1542 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure ............................................................................................................................. .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle Speed (Minimum) 6 psi (at normal operating temperature) CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. @ 3000 rpm 30 - 80 psi BYPASS RELIEF VALVE SETTING 9 - 15 psi OIL PRESSURE SWITCH ACTUATING PRESSURE 5 - 7 psi Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications INTAKE MANIFOLD BOLTS Install the intake manifold bolts and tighten as follows: Step 1: Tighten bolts 1 - 4 to 8 Nm (72 in. lbs.) in incremental steps of 1.4 Nm (12 in. lbs.). - Step 2: Tighten bolts 5 - 12 to 8 Nm (72 in. lbs.) - Step 3: Check all bolts are torqued to 8 Nm (72 in. lbs.) - Step 4: Tighten all bolts in sequence to 16 Nm (12 ft. lbs.) - Step 5: Check all bolts are torqued to 16 Nm (12 ft. lbs.) PLENUM PAN MOUNTING BOLTS Tighten plenum pan mounting bolts as follows: Step 1: Tighten bolts to 5.4 Nm (48 in. lbs.) - Step 2: Tighten bolts to 9.5 Nm (84 in. lbs.) - Step 3: Check all bolts are torqued to 9.5 Nm (84 in. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 1554 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .............................................................................................................. .................................................. 23 Nm (200 in. lbs) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Additional Information Intake Manifold: Service and Repair Additional Information Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Additional Information > Page 1557 Intake Manifold: Service and Repair Intake Manifold REMOVAL 1. Disconnect the battery negative cable. 2. Drain the cooling system. 3. Remove the A/C compressor. Refer to Heating and Air Conditioning. 4. Remove the generator. Refer to Starting and Charging. 5. Remove the accessory drive bracket. 6. Remove the air cleaner assembly and air inlet hose. 7. Perform the fuel pressure release procedure. Refer to Powertrain Management. 8. Disconnect the fuel supply line from the fuel rail. Refer to Powertrain Management. 9. Disconnect the accelerator linkage and, if so equipped, the speed control and transmission kickdown cables. 10. Remove the distributor cap and wires. 11. Disconnect the coil wires. 12. Disconnect the coolant temperature sending unit wire. 13. Disconnect the heater hoses and bypass hose. 14. Remove the closed crankcase ventilation and evaporation control systems. 15. Remove intake manifold bolts. 16. Lift the intake manifold and throttle body out of the engine compartment as an assembly. 17. Remove and discard the flange side gaskets and the front and rear cross-over gaskets. Fig. 40 18. Remove the throttle body bolts and lift the throttle body off the intake manifold (Fig. 40). Discard the throttle body Basket. INSTALLATION 1. If the plenum pan was removed, position pan gasket and pan. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Additional Information > Page 1558 Fig. 41 2. Install plenum pan retaining bolts (Fig. 41). 3. Tighten plenum pan mounting bolts as follows: - Step 1. Tighten bolts to 5.4 Nm (24 in. lbs.) - Step 2. Tighten bolts to 9.5 Nm (84 in. lbs.) - Step 3. Check all bolts are at 9.5 Nm (84 in. lbs.) 4. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 in. lbs.) torque. 5. Apply a bead of Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. The sealant bead height should be slightly higher than the cross-over gaskets, approximately 5 mm (0.2 inch). An excessive amount of sealant is not required to ensure a leak proof seal, and an excessive amount of sealant may reduce the effectiveness of the flange gasket. Fig. 42 6. Install the front and rear cross-over gaskets onto the engine (Fig. 42). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Additional Information > Page 1559 Fig. 43 7. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs (Fig. 43). The words MANIFOLD SIDE should be visible on the center of each flange gasket. 8. Carefully lower intake manifold into position on the cylinder block and cylinder heads. long studs at the front and rear of the manifold will help to align the intake manifold. After intake manifold is in place, inspect to make sure seals are in place. Remove alignment studs if used. Fig. 44 9. The following torque sequence duplicates the expected results of the automated assembly system (Fig. 44). - Step 1-Tighten bolts 1 thru 4, in sequence, to 8 Nm (72 in. lbs.) torque. Tighten in alternating steps 1.4 Nm (12 in. lbs.) torque at a time. - Step 2-Tighten bolts 5 thru 12, in sequence, to 8 Nm (72 in. lbs.) torque. - Step 3-Check that all bolts are tightened to 8 Nm (72 in. lbs.) torque. - Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. - Step 5-Check that all bolts are tightened to 16 Nm (12 ft. lbs.) torque. 10. Install closed crankcase ventilation and evaporation control systems. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Additional Information > Page 1560 11. Install the coil wires. 12. Connect the coolant temperature sending unit wire. 13. Connect the heater hoses and bypass hose. 14. Install distributor cap and wires. 15. Connect the accelerator linkage and, if so equipped, the speed control and transmission kickdown cables. 16. Install the fuel supply line to the fuel rail. 17. Install the accessory drive bracket and A/C compressor. 18. Install the generator and accessory drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. 19. Install the air cleaner assembly and air inlet hose. 20. Fill cooling system. 21. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure ............................................................................................................................. .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair The service seal is a 2 piece, viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can only be installed with the rear main bearing cap removed. UPPER SEAL -CRANKSHAFT REMOVED REMOVAL 1. Remove the crankshaft. Discard the old upper seal. INSTALLATION 1. Clean the cylinder block rear cap mating surface. Make sure the seal groove is free of debris. 2. Lightly oil the new upper seal lips with engine oil. 3. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 4. Position the crankshaft into the cylinder block. 5. Lightly oil the new lower seal lips with engine oil. 6. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. Fig. 77 7. Apply 5 mm (0.20 inch) drop of Moping Gasket Maker, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 8. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 9. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 10. Install oil pump. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1569 Fig. 78 11. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 12. Install new front crankshaft oil seal. 13. Immediately install the oil pan. UPPER SEAL - CRANKSHAFT INSTALLED REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap. Remove and discard the old lower oil seal. 4. Carefully remove and discard the old upper oil seal. INSTALLATION 1. Clean the cylinder block mating surfaces before oil seal installation. Check for burr at the oil hole on the cylinder block mating surface to rear cap. 2. Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear bearing cap. 3. Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. To assure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing towards the rear of the engine. 4. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. 5. Apply 5 mm (0.20 inch) drop of Mopar Gasket Maker, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. 6. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 7. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 Nm (85 ft. lbs.) torque. 8. Install oil pump. 9. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Immediately install the oil pan. LOWER SEAL REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap and discard the old lower seal. INSTALLATION 1. Clean the rear main cap mating surfaces including the oil pan gasket groove. 2. Carefully install a new upper seal (refer to Upper Seal Replacement - Crankshaft Installed procedure above). 3. Lightly oil the new lower seal lips with engine oil. 4. Install a new lower seal in bearing cap with the white paint facing the rear of engine. 5. Apply 6 mm (0.20 inch) drop of Mopar Gasket Maker, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1570 6. ED align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 7. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 8. Install oil pump. 9. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Immediately install the oil pan. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair The oil seal can be replaced without removing the timing chain cover provided the cover is not misaligned. 1. Disconnect the negative cable from the battery. 2. Remove vibration damper. 3. If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly. 4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover. Fig. 74 5. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 74). Seat the oil seal in the groove of the tool. Fig. 75 6. Position the seal and tool onto the crankshaft (Fig. 75). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1574 Fig. 76 7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 76). 8. Remove the vibration damper bolt and seal installation tool. 9. Inspect the seal flange on the vibration damper. 10. Install the vibration damper. 11. Connect the negative cable to the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair 1. Remove the air cleaner. 2. Remove cylinder head covers and spark plugs. 3. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 4. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at TDC on the compression stroke. 5. Remove rocker arms. 6. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620 - 689 kPa (90 - 100 psi) air pressure. 7. Using Valve Spring Compressor Tool MD-998772A with adapter 6716A, compress valve spring and remove retainer valve locks and valve spring. 8. Install seals on the exhaust valve stem and position down against valve guides. 9. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 10. Follow the same procedure on the remaining 7 cylinders using the firing sequence 1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 11. Remove adapter from the No.1 spark plug hole and install spark plugs. 12. Install rocker arms. 13. Install covers and coil wire to distributor. 14. Install air cleaner. 15. Road test vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1585 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 1586 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 50 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Procedures Camshaft Gear/Sprocket: Procedures Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Additional Information Crankshaft Gear/Sprocket: Service and Repair Additional Information Refer to Engine Service and Repair for "Standard Service Procedures", "Disassembly and Assembly of Subassemblies" and "Cleaning and Inspection" information. See: Service and Repair/Procedures "Standard Service Procedures" typically covers service procedures, machining, fitting necessary as part of engine overhaul: - Cylinder Block and Bore - Connecting Rod and Bearings - Fitting - Crankshaft and Bearings - Fitting - Valve train components (Valves, Seats, Springs, Seats, Rockers, etc) - Engine Oil - Checking and Changing - Pistons and Rings - Fitting "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Cylinder Block - Hydraulic Tappets (if equipped) - Oil Pump - Valve Service (See also: Valve, Intake/Exhaust) "Cleaning and Inspection" typically covers service of the following components: - Cylinder Head - Cylinder Block - Camshaft and Journals - Crankshaft and Journals - Intake and Exhaust Manifolds - Valve Train Components (Valves, Seats, Springs, Seats, Rockers, etc) If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair/Procedures Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Camshaft Thrust Plate Bolts ............................. ..................................................................................................................................... 24 Nm (210 in. lbs.) Timing Chain Case Cover Bolts ................................................................................................... ............................................................ 41 Nm (30 ft. lbs.) Crankshaft Pulley Bolts ....................................................................................................................... .................................................. 24 Nm (210 in. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1600 Timing Chain: Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 1601 Timing Chain: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove Timing Chain Cover. 3. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks as shown in image. 4. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION 1. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 2. Place timing chain around both sprockets. 3. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 4. Lift sprockets and chain (keep sprockets tight against the chain in position as described). Fig. 57 5. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks (Fig. 57). 6. Install the camshaft bolt. Tighten the bolt to 68 Nm (50 ft. lbs.) torque. 7. Check camshaft end play. The end play should be 0.051 - 0.152 mm (0.002 - 0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. 8. Install the timing chain cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Case Cover Bolts 30 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1605 Timing Cover: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Drain cooling system. 3. Remove the serpentine belt. 4. Remove water pump (refer to Cooling System). 5. Remove power steering pump (refer to Steering and Suspension). 6. Remove vibration damper. 7. Remove fuel lines (refer to Powertrain Management) 8. Loosen oil pan bolts and remove the front bolt at each side. 9. Remove the cover bolts. 10. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. Fig. 53 11. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of cover (Fig. 53). INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. 2. The water pump mounting surface must be cleaned. 3. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. Fig. 54 4. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 54). Seat the oil seal in the groove of the tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1606 Fig. 55 5. Position the seal and tool onto the crankshaft (Fig. 55). 6. Tighten the 4 lower chain case cover bolts to 13 Nm (10 ft. lbs.) to prevent the cover from tipping during seal installation. Fig. 56 7. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 56). 8. Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly. 9. Tighten chain case cover bolts to 41 Nm (30 ft. lbs.) torque. Tighten oil pan bolts to 24 Nm (215 in. lbs.) torque. 10. Remove the vibration damper bolt and seal installation tool. 11. Install vibration damper. 12. Install water pump and housing assembly using new gaskets (refer to Cooling System). Tighten bolts to 41 Nm (30 ft. lbs.) torque. 13. Install power steering pump (refer to Steering and Suspension). 14. Install the serpentine belt. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1607 15. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 16. Position the fan shroud and install the bolts. Tighten the bolts to 11 Nm (95 in. lbs.) torque. 17. Fill cooling system. 18. Connect the negative cable to the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 1613 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). Fig. 33 - Air Cleaner Housing Assembly 2. Release housing cover from locating tabs on housing (Fig. 33) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1625 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1630 Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Cable Resistance Spark Plug Cable Resistance Minimum 250 ohms at 1 in 3000 ohms at 12 in Maximum 1000 ohms at 1 in 12000 ohms at 12 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1638 Ignition Cable: Service Precautions CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1639 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1640 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression~on. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1641 Ignition Cable: Service and Repair Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection - Internal - Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Type RC12LC4 Electrode Gap 1.01 mm Torque 35 - 41 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1652 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12LC4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1653 Spark Plug: Description and Operation All engines use resistor type spark plugs. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1654 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Normal Operating Normal Operation And Cold (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. On these engines, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1655 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. Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1656 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. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1657 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1658 Spark Plug: Service and Repair REMOVAL Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 1. Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 3. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 4. Inspect spark plug condition. Refer to Spark Plug Conditions. Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode fiat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Gap Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1659 Setting Spark Plug Gap-Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Cylinder Compression Pressure 689.5 kPa (100 psi) Maximum Variation Between Cylinders 25 % Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1663 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the third revolution. Continue the test for the remaining cylinders. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump to Chain Cover-Bolts 30 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Water Pump: Service and Repair Water Pump REMOVAL The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect battery negative cable. 2. Drain cooling system. Refer to Cooling System-Draining and Filling. 3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 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). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. Remove upper radiator hose clamp and hose at radiator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1672 5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) and Special Tool 6958 Spanner Wrench with Adapter Pins 8346 can be used. Place Special Tool 6958 Spanner Wrench onto the water pump pulley with Adapter Pins 8346 inserted into the holes on the pulley to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 9. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1673 10. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 11. Remove lower radiator hose clamp and remove lower hose at water pump. 12. Remove heater hose clamp and heater hose from heater hose coolant return tube. 13. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 14. Remove seven water pump mounting bolts. 15. Loosen clamp at water pump end of bypass hose . Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1674 INSTALLATION 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Relax tension from belt tensioner. Install accessory drive belt. CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. The correct belt with correct length must be used. 10. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 11. Install fan shroud. 12. Install fan blade/viscous fan drive assembly to water pump shaft. 13. Fill cooling system. Refer to Cooling System-Draining and Refilling. 14. Connect battery negative cable. 15. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump > Page 1675 Water Pump: Service and Repair Cleaning and Inspection CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1681 Coolant: Fluid Type Specifications Use 50/50 mixture of ethylene-glycol antifreeze containing Alugard 340-2 and low mineral content water. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1682 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning Coolant Line/Hose: Service and Repair Without Air Conditioning REMOVAL 1. Partially drain cooling system. Refer to COOLING SYSTEM-DRAINING and FILLING. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 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). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle. INSTALLATION 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1687 Coolant Line/Hose: Service and Repair With Air Conditioning REMOVAL If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor. WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. REFER TO REFRIGERANT WARNINGS IN HEATING AND AIR CONDITIONING. 1. Disconnect battery negative cable. 2. Partially drain cooling system. Refer to COOLING SYSTEM-DRAINING and FILLING. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. 6. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1688 and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body control cables. Refer to ACCELERATOR PEDAL and THROTTLE CABLE in Powertrain Management for procedure. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts (number 1 and 2). 13. Remove six bracket bolts (number 3). 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3) to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. 10. Relax tension from belt tensioner. Install drive belt. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Without Air Conditioning > Page 1689 CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. The correct belt with correct length must be used. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Connect battery negative cable. 15. Fill cooling system. Refer to Draining and Filling Cooling System. 16. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair NOTE: The coolant reservoir/overflow tank is integral to the upper fan shroud. Refer to Fan Shroud for proper removal/installation procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Radiator Fan Motor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1722 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1723 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1724 Radiator Cooling Fan Motor Relay: Description and Operation RADIATOR COOLING FAN RELAY - PCM OUTPUT The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103 °C (217 °F). It will then de-energize when coolant temperature drops to approximately 98 °C (208 °F). Refer to Cooling Systems for additional information. Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Refer to Heating and Air Conditioning for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair CLEANING Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades. INSPECTION WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. 1. Remove fan blade assembly from viscous fan drive unit (four bolts). 2. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (0.090 inch). Test all blades in this manner. 3. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan Blade to Fan Drive Bolts 17 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 1731 Fan Clutch: Service and Repair VISCOUS FAN DRIVE REMOVAL 1. Disconnect battery negative cable. 2. The thermal viscous fan drive/fan blade assembly is attached (threaded) to water pump hub shaft. Remove fan blade/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) and Special Tool 6958 Spanner Wrench with Adapter Pins 8346 can be used to hold the pulley still to prevent pulley from rotating. 3. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 1732 4. Do not unbolt fan blade assembly from viscous fan drive at this time. 5. Remove upper fan shroud attaching hardware. 6. Remove upper fan shroud and fan blade/viscous fan drive from vehicle. 7. After removing fan blade/viscous fan drive assembly, do not place viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. 8. Remove four bolts securing fan blade assembly to viscous fan drive. INSTALLATION 1. Install fan blade assembly to viscous fan drive. Tighten bolts to 23 Nm (17 ft. lbs.) torque. 2. Position fan blade/viscous fan drive assembly and upper shroud into vehicle. 3. Install fan shroud retaining screws. 4. Install fan blade/viscous fan drive assembly to water pump shaft. 5. Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 1739 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1740 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1741 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1742 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1743 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Mounting Bolts 50 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the heater-A/C housing, under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1750 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1751 Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 1752 Heater Core: Service and Repair WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions - FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Heater Core Remove/Install 2. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Temperature Indicator ......................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Unscrew draincock stem (counterclockwise rotation). When stem is completely unscrewed, pull it from radiator tank and draincock body. 2. Using a pair of needle nose pliers, compress draincock body and pull straight out of radiator. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Page 1761 1. Install draincock stem loosely into body. The draincock assembly cannot be installed if stem is threaded into the body. 2. Push draincock assembly into opening in radiator tank. It will snap into place when fully seated. 3. Tighten draincock (clockwise) to 2.0 - 2.7 Nm (18 - 25 inch lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair Radiator Cap: Service and Repair CLEANING Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage to the seal in the radiator cap. INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Power Distribution Center Radiator Fan Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1769 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1770 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Radiator Fan Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1771 Radiator Cooling Fan Motor Relay: Description and Operation RADIATOR COOLING FAN RELAY - PCM OUTPUT The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The electric radiator cooling fan is controlled by the Powertrain Control Module (PCM) through the radiator cooling fan relay. The PCM will activate the relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relay is energized when coolant temperature is above approximately 103 °C (217 °F). It will then de-energize when coolant temperature drops to approximately 98 °C (208 °F). Refer to Cooling Systems for additional information. Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated. Refer to Heating and Air Conditioning for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 1779 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1780 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1781 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1782 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 1783 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Temperature Indicator ......................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Starts to Open 195 F Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1790 Thermostat: Service and Repair REMOVAL WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. Factory installed thermostat housings on 5.2L/5.9L engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. 1. Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below thermostat. Refer to Draining Cooling System. 3. Air Conditioned vehicles: Remove support bracket (generator mounting bracket-to-intake manifold) located near rear of generator. 4. On air conditioning equipped vehicles, the generator must be partially removed. a. Remove generator drive belt as follows: Drive belts on 5.2L/5.9L engines are equipped with a spring loaded automatic belt tensioner. b. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. c. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. d. Remove belt from vehicle. e. Remove two generator mounting bolts. Do not remove any wiring at generator. If equipped with 4WD, unplug 4WD indicator lamp wiring Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1791 harness (located near rear of generator). f. Remove generator. Position generator to gain access for thermostat gasket removal. 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). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 5. Remove upper radiator hose clamp and upper radiator hose at thermostat housing. 6. Position wiring harness (behind thermostat housing) to gain access to thermostat housing. 7. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket. INSTALLATION 1. Clean mating areas of intake manifold and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and over thermostat. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1792 4. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing. For adequate clearance, this must be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold. 5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque. 6. Install upper radiator hose to thermostat housing. 7. Air Conditioned vehicles: CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct engine belt routing. The correct belt with correct length must be used. a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.). b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque. c. Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1793 d. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. e. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 8. Fill cooling system. Refer to Refilling Cooling System. 9. Connect battery negative cable. 10. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Bolts 225 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump to Chain Cover-Bolts 30 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Water Pump: Service and Repair Water Pump REMOVAL The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect battery negative cable. 2. Drain cooling system. Refer to Cooling System-Draining and Filling. 3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 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). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. 4. Remove upper radiator hose clamp and hose at radiator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1802 5. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) and Special Tool 6958 Spanner Wrench with Adapter Pins 8346 can be used. Place Special Tool 6958 Spanner Wrench onto the water pump pulley with Adapter Pins 8346 inserted into the holes on the pulley to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 6. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 7. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 8. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 9. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1803 10. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 11. Remove lower radiator hose clamp and remove lower hose at water pump. 12. Remove heater hose clamp and heater hose from heater hose coolant return tube. 13. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 14. Remove seven water pump mounting bolts. 15. Loosen clamp at water pump end of bypass hose . Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1804 INSTALLATION 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. 9. Relax tension from belt tensioner. Install accessory drive belt. CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. The correct belt with correct length must be used. 10. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 11. Install fan shroud. 12. Install fan blade/viscous fan drive assembly to water pump shaft. 13. Fill cooling system. Refer to Cooling System-Draining and Refilling. 14. Connect battery negative cable. 15. Start and warm the engine. Check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump > Page 1805 Water Pump: Service and Repair Cleaning and Inspection CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, Water leaks from shaft seal, Loose or rough turning bearing or Impeller rubbing either the pump body or timing chain case/cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold to Cylinder Head Bolts/Nuts 25 ft.lb Tighten the exhaust manifold bolts starting with the center arm and work outwards. Exhaust Pipe to Manifold Bolts 23 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1810 Exhaust Manifold: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Raise the vehicle. 3. Remove the exhaust pipe to manifold nuts. 4. Lower the vehicle. 5. Remove three nuts, heat shield and washers from the right side exhaust manifold, if necessary. 6. Remove two nuts, heat shield and washers from the left side exhaust manifold, if necessary. 7. Remove bolts, nuts and washers attaching manifold to cylinder head. 8. Remove manifold from the cylinder head. INSTALLATION CAUTION: If the studs came out with the nuts when removing the exhaust manifold, install new studs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1811 1. Position the exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs. 2. Install new bolt and washer assemblies in the remaining holes. Start at the center arm and work outward. Tighten the bolts and nuts to 24 Nm (18 ft. lbs.) torque. 3. Position three washers, heat shield and nuts on the right side exhaust manifold. Tighten nuts to 24 Nm (18 ft. lbs.). 4. Position two washers, heat shield and nuts on the left side exhaust manifold. Tighten nuts to 24 Nm (18 ft. lbs.). 5. Raise the vehicle. 6. Assemble the exhaust pipe to the exhaust manifold and secure with bolts, nuts and washers. Tighten these nuts to 27 Nm (20 ft. lbs.) torque. 7. Lower the vehicle. 8. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe to Manifold Nuts 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor. REMOVAL 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration. 3. Disconnect the oxygen sensor(s). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1817 4. Remove the exhaust manifold-to-exhaust pipe nuts. 5. Remove exhaust pipe/converter to muffler exhaust clamp. 6. Disconnect the exhaust pipe/catalytic converter from muffler. 7. Remove the exhaust pipe. INSTALLATION 1. Align and connect the exhaust pipe/catalytic converter to the muffler. Install exhaust clamp and tighten clamp nuts to 42 Nm (31 ft. lbs.) torque. 2. Connect the exhaust pipe(s) to the exhaust manifold. Tighten the nuts to 34 Nm (25 ft. lbs.) torque. 3. Connect oxygen sensor connector(s). 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 1818 Exhaust Pipe: Service and Repair Tailpipe WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage-the wiring and/or sensor. REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect tailpipe from rear hanger bracket. 4. Remove muffler to tailpipe exhaust clamp. 5. Heat connection with an oxygen/acetylene torch and twist tailpipe out of muffler. INSTALLATION 1. Install tailpipe to muffler. Install exhaust clamp and start nuts by hand. 2. Connect tailpipe hanger. 3. Align tailpipe and tighten exhaust clamp nuts to 42 Nm (31 ft. lbs.). 4. Lower vehicle and connect battery negative cable. 5. Start engine and check for exhaust leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield Nuts 60 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1822 Heat Shield: Service and Repair REMOVAL 1. Raise and support the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1823 2. Remove the screws and nuts holding the heat shields to the frame and floor pan. When removing muffler heat shield, the muffler front and rear support hangers must be removed first. Be sure to disconnect both oxygen sensor connectors. 3. Slide the shield out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the screws/nuts to 7 Nm (60 inch lbs.) torque. Tighten the muffler hangers to 23 Nm (200 inch lbs.). 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler Hanger Bolts 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 1827 Muffler: Service and Repair WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, WEAR PROTECTIVE EYE COVERING AND DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing or replacing exhaust system components, be sure to disconnect all oxygen sensor connectors. Allowing the exhaust system to hang by the harness will damage the wiring and/or sensor. REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Remove muffler to exhaust pipe/catalytic converter and tailpipe clamps. 4. Remove tailpipe from hanger isolator. Heat muffler to tailpipe with an oxygen/acetylene torch and twist tailpipe out of muffler. 5. Disconnect muffler from hanger isolators. 6. Heat muffler to exhaust pipe/catalytic converter connection and twist muffler off of converter pipe. INSTALLATION 1. Install muffler to exhaust pipe/catalytic converter and tailpipe. Install exhaust clamps and start nuts by hand. 2. Connect muffler to rear muffler hanger. 3. Connect tailpipe to rear hanger. 4. Align muffler and tighten exhaust clamp nuts to 42 Nm (31 ft. lbs.). 5. Lower vehicle and connect battery negative cable. 6. Start engine and check for exhaust leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up Central Timer Module: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up > Page 1839 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 1845 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 1846 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Central Timer Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Central Timer Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 1894 Central Timer Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation Central Timer Module: Description and Operation System Description and Functional Operation For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2000 DN consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication (CCD Bus) of this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII (R) via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Central Locking Feature - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Remote Radio Switches - Remote Keyless Entry (RKE) - Vehicle Theft Security System (VTSS) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1897 The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for approximately six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Seat belt warning - Malfunction Indicator Lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) - Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini- trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all reset table conditions will be reset. This will occur only if a resettable function (AVG ECO, Trip Odometer, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1898 Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door key cylinder switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned on by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRBIII (R) under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRBIII (R), or customer programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features. The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate (DN) and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRBIII (R). The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the liftgate are equipped with key cylinder mux switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRBIII (R), or by using the customer programming sequence. Through the DRBIII (R), erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Speed Sensitive Intermittent Wipers The DN truck equipped with a highline CTM will utilize speed sensitive intermittent wipers. Only a highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Diagnostics Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1899 The CTM is fully addressable with the DRBIII (R) and it is the recommended method for diagnosis. The CTM reports up to 7 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII (R). The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1900 corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum for 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If the malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal - Logic Capacitor Low - AECM Output Driver Circuit Open - Firing Capacitor Low - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Shorted to Battery - Driver Squib Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Shorted to Battery - Passenger Squib Shorted to Ground - Warning Lamp Circuit Open/Shorted - No Cluster CCD Message - Cluster Message Mismatch Central Timer Module Diagnostic Trouble Codes Key Cylinder Lock Switch Failure/Lock - Door Lock Switch Failure - Door Unlock Switch Failure - Key Cylinder Lock Switch Failure/Unlock - Wiper Park Switch Failure - EEPROM Checksum Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1901 - Internal ROM Test Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1902 Central Timer Module: Description and Operation Central Timer Module For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 1903 These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1906 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM-CHIME inoperative Chime Inoperative With Any Lamp or Gauge Warning Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1907 Test 1 - 3 SYMPTOM CHIME INOPERATIVE WITH ANY LAMP OR GAUGE WARNING POSSIBLE CAUSES - Open tone request signal circuit - Instrument cluster- chime inoperative with any warning lamp - CTM - Tone request signal circuit Chime Inoperative With Exterior Lights On and Drivers Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1908 Test 1 - 4 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LAMPS ON, DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-CHIME inoperative with headlamp switch - Headlamp switch key in ignition switch sense circuit open - Headlamp switch - key in ignition switch sense open Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1909 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1910 Test 4 - 8 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1911 - Key-in ignition switch sense circuit open Chime Remains On With Ignition On Test 1 - 3 SYMPTOM CHIME REMAINS ON WITH IGNITION ON POSSIBLE CAUSES - Instrument cluster-chime stays ON - Tone request circuit shorted ground - CTM-CHIME stays ON Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1912 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Key-in IGN switch sense circuit shorted ground - Shorted key-in switch - Headlamp switch shorted test, for chime system Doors Lock With Key In Ignition & Front Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1913 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1914 Test 4 - 8 SYMPTOM DOORS LOCK WITH KEY IN IGNITION & FRONT DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1915 - Key-in ignition switch sense circuit open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1916 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1917 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1918 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1919 Central Timer Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1920 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 1921 Central Timer Module: Tools and Equipment DRBIII (R) (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1930 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1931 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1932 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1937 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1938 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1939 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1940 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1946 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1947 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: Customer Interest PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1952 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1953 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1959 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1960 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 1961 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1966 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1967 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1968 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 1969 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1974 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1975 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1980 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1981 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1987 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 1988 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1993 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 1994 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2000 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2001 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2002 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2007 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2008 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2009 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2010 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2011 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 3 - 5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2012 Powertrain Control Module: Locations Module Locations Powertrain Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2013 Fig. 29 - PCM Location And Mounting The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 Dodge JTEC System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description Powertrain Control Module: Description and Operation General Description POWERTRAIN CONTROL MODULE Fig. 1 - PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC (Jeep/Truck Engine Controller). The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto Shutdown (ASD) sense - Battery temperature - Battery voltage Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2041 - Ignition circuit sense (ignition switch in ON/OFF/CRANK/RUN position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. Sensor return is a low-noise, low-current, dedicated ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2042 Powertrain Control Module: Description and Operation PCM Operating Modes PCM OPERATING MODES As input signals to the PCM change, the PCM adjusts its response to 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. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. 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 air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch ON (Engine OFF) Mode When the ignition switch activates the fuel injection system, the following actions occur: 1. The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the ignition key is in the "ON" position and the engine is not running (0 rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Engine Start-up Mode This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive the camshaft and crankshaft signal within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequence. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode This is an open loop mode. The PCM adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. Cruise or Idle Mode When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Acceleration Mode Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2043 This is a closed loop mode. The PCM recognizes an increase in throttle position and a decrease in Manifold Vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Deceleration Mode This is a closed loop mode. The PCM recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Wide Open Throttle Mode This is an open mode. The Throttle Position Sensor notifies the PCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 2044 Powertrain Control Module: Service and Repair Fig. 29 - PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2048 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2049 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2050 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2051 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2052 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2053 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Upstream and Downstream Relays are located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2057 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2058 Oxygen Sensor Relay: Diagrams Power Distribution Center Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2059 Oxygen Sensor Upstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2060 Oxygen Sensor Relay: Description and Operation OXYGEN SENSOR HEATER RELAYS - PCM OUTPUT The 2 oxygen (O2) sensor heater relays (upstream and downstream) are located in the Powertrain Distribution Center (PDC). Engines equipped with the California (NAE) Emissions Package use four O2 sensors. Two of the four sensor heater elements (upstream sensors 1/1 and 211) are controlled by the upstream heater relay through output signals from the Powertrain Control Module (PCM). The other two heater elements (downstream sensors 1/2 and 2/2) are controlled by the downstream heater relay through output signals from the PCM. To avoid a large simultaneous current surge, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2061 Oxygen Sensor Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The oxygen sensor heater relays are located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2066 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2067 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2068 Fuel Pump Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2069 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY - PCM OUTPUT The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2070 Fuel Pump Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 13). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2071 Fuel Pump Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 17). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2075 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2076 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2077 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2078 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2079 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2080 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2086 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2087 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2088 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2089 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 2093 Brake Pressure Switch: Description and Operation BRAKE SWITCH - PCM INPUT When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2098 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2099 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2100 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2101 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 2107 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2108 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2109 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2110 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2111 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2115 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2116 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2117 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2118 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2119 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel level sensor (fuel gauge sending unit) is located on the fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2123 Fuel Pump Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2124 Fuel Level Sensor: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2125 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR - PCM INPUT The fuel level sensor (fuel gauge sending unit) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multiplexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multiplex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2126 Fuel Level Sensor: Testing and Inspection The fuel level sensor contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the level sensor only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air Temp. Sensor 28 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2130 Intake Air Temperature (IAT) Sensor: Locations Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The Intake Manifold Air Temperature (IAT) sensor is located in the front/side of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2131 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2132 Intake Air Temperature (IAT) Sensor: Description and Operation INTAKE MANIFOLD AIR TEMPERATURE SENSOR - PCM INPUT The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2133 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2137 Manifold Absolute Pressure (MAP) Sensor: Locations IAC/MAP/TPS Fig. 26 - MAP Sensor Location The MAP sensor is located on the front of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2138 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2139 Manifold Absolute Pressure (MAP) Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - PCM INPUT The Manifold Absolute Pressure (MAP) sensor is attached to the side of the engine throttle body with 2 screws. The sensor is connected to the throttle body with a rubber L-shaped fitting. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V For a pressure swing of 0 - 15 psi, the voltage changes 4.0 V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor ( TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2140 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 26 - MAP Sensor Location Fig. 27 - MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2141 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2145 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2146 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor 30 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2152 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions Oxygen Sensor: Diagrams California Emissions Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions > Page 2155 Oxygen Sensor: Diagrams Federal Emissions Oxygen Sensor 1/1 Upstream (except California) Oxygen Sensor 1/2 Downstream (except California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2156 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2157 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2158 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S) - PCM INPUT The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. Non-California Engines On certain non-California (Federal) emissions packages, 2 sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Engines On certain California emissions packages, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. OXYGEN SENSOR OPERATION An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7 to 1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heaters/Heater Relays Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used. The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on these engines. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° F - 1100 °F (500 °C - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor (Certain Non-California Emissions) The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined Will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor (Certain Non-California Emissions) The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2159 Downstream Sensors (Certain California Emissions) Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2160 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2161 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2165 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2166 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2167 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2168 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2172 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2177 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2178 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2179 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2180 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2181 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2197 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE - PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Refer to Odometer and Trip Odometer in Instrument Panel for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2202 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2203 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2204 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2205 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2211 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2212 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2213 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2214 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2218 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2219 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2220 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2221 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2222 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2227 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2228 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2229 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2230 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2231 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 2232 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2238 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). Fig. 33 - Air Cleaner Housing Assembly 2. Release housing cover from locating tabs on housing (Fig. 33) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2250 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2255 Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Cable Resistance Spark Plug Cable Resistance Minimum 250 ohms at 1 in 3000 ohms at 12 in Maximum 1000 ohms at 1 in 12000 ohms at 12 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2263 Ignition Cable: Service Precautions CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2264 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2265 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression~on. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2266 Ignition Cable: Service and Repair Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection - Internal - Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Type RC12LC4 Electrode Gap 1.01 mm Torque 35 - 41 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2277 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12LC4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2278 Spark Plug: Description and Operation All engines use resistor type spark plugs. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2279 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Normal Operating Normal Operation And Cold (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. On these engines, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2280 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. Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2281 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. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2282 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2283 Spark Plug: Service and Repair REMOVAL Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 1. Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 3. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 4. Inspect spark plug condition. Refer to Spark Plug Conditions. Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode fiat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Gap Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2284 Setting Spark Plug Gap-Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Cylinder Compression Pressure 689.5 kPa (100 psi) Maximum Variation Between Cylinders 25 % Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2288 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the third revolution. Continue the test for the remaining cylinders. Refer to Engine Specifications for the correct engine compression pressures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air Temp. Sensor 28 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2296 Intake Air Temperature (IAT) Sensor: Locations Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The Intake Manifold Air Temperature (IAT) sensor is located in the front/side of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2297 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2298 Intake Air Temperature (IAT) Sensor: Description and Operation INTAKE MANIFOLD AIR TEMPERATURE SENSOR - PCM INPUT The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2299 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2303 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2304 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2305 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2306 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 2315 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 2321 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 2322 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Central Timer Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Central Timer Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2370 Central Timer Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation Central Timer Module: Description and Operation System Description and Functional Operation For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2000 DN consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication (CCD Bus) of this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII (R) via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Central Locking Feature - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Remote Radio Switches - Remote Keyless Entry (RKE) - Vehicle Theft Security System (VTSS) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2373 The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for approximately six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Seat belt warning - Malfunction Indicator Lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) - Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini- trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all reset table conditions will be reset. This will occur only if a resettable function (AVG ECO, Trip Odometer, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2374 Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door key cylinder switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned on by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRBIII (R) under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRBIII (R), or customer programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features. The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate (DN) and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRBIII (R). The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the liftgate are equipped with key cylinder mux switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRBIII (R), or by using the customer programming sequence. Through the DRBIII (R), erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Speed Sensitive Intermittent Wipers The DN truck equipped with a highline CTM will utilize speed sensitive intermittent wipers. Only a highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Diagnostics Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2375 The CTM is fully addressable with the DRBIII (R) and it is the recommended method for diagnosis. The CTM reports up to 7 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII (R). The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2376 corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum for 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If the malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal - Logic Capacitor Low - AECM Output Driver Circuit Open - Firing Capacitor Low - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Shorted to Battery - Driver Squib Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Shorted to Battery - Passenger Squib Shorted to Ground - Warning Lamp Circuit Open/Shorted - No Cluster CCD Message - Cluster Message Mismatch Central Timer Module Diagnostic Trouble Codes Key Cylinder Lock Switch Failure/Lock - Door Lock Switch Failure - Door Unlock Switch Failure - Key Cylinder Lock Switch Failure/Unlock - Wiper Park Switch Failure - EEPROM Checksum Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2377 - Internal ROM Test Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2378 Central Timer Module: Description and Operation Central Timer Module For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2379 These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2382 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM-CHIME inoperative Chime Inoperative With Any Lamp or Gauge Warning Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2383 Test 1 - 3 SYMPTOM CHIME INOPERATIVE WITH ANY LAMP OR GAUGE WARNING POSSIBLE CAUSES - Open tone request signal circuit - Instrument cluster- chime inoperative with any warning lamp - CTM - Tone request signal circuit Chime Inoperative With Exterior Lights On and Drivers Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2384 Test 1 - 4 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LAMPS ON, DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-CHIME inoperative with headlamp switch - Headlamp switch key in ignition switch sense circuit open - Headlamp switch - key in ignition switch sense open Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2385 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2386 Test 4 - 8 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2387 - Key-in ignition switch sense circuit open Chime Remains On With Ignition On Test 1 - 3 SYMPTOM CHIME REMAINS ON WITH IGNITION ON POSSIBLE CAUSES - Instrument cluster-chime stays ON - Tone request circuit shorted ground - CTM-CHIME stays ON Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2388 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Key-in IGN switch sense circuit shorted ground - Shorted key-in switch - Headlamp switch shorted test, for chime system Doors Lock With Key In Ignition & Front Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2389 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2390 Test 4 - 8 SYMPTOM DOORS LOCK WITH KEY IN IGNITION & FRONT DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2391 - Key-in ignition switch sense circuit open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2392 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2393 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2394 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2395 Central Timer Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2396 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2397 Central Timer Module: Tools and Equipment DRBIII (R) (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations > Page 2402 Brake Pressure Switch: Description and Operation BRAKE SWITCH - PCM INPUT When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2407 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2408 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2409 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2410 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 2416 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2417 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2418 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2419 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2420 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2424 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2425 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2426 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2427 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2428 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Data Link Connector The Data Link Connector (DLC) is located at the lower edge of the instrument panel near the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2452 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2453 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2454 Data Link Connector Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2455 Data Link Connector: Description and Operation DATA LINK CONNECTOR - PCM INPUT AND OUTPUT The Data Link Connector (DLC) is located at the lower edge of the instrument panel near the steering column. The 16-way data link connector (diagnostic scan tool connector) links the Diagnostic Readout Box (DRB) scan tool or the Mopar Diagnostic System (MDS) with the Powertrain Control Module (PCM). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2464 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2465 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2466 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2471 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2472 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2473 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2474 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2480 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2481 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: Customer Interest PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2486 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2487 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2493 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2494 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2495 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2500 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2501 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2502 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2503 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2508 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2509 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2514 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2515 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2521 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2522 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2527 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2528 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2534 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2535 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2536 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2541 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2542 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2543 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2544 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2545 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 3 - 5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2546 Powertrain Control Module: Locations Module Locations Powertrain Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2547 Fig. 29 - PCM Location And Mounting The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 Dodge JTEC System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description Powertrain Control Module: Description and Operation General Description POWERTRAIN CONTROL MODULE Fig. 1 - PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC (Jeep/Truck Engine Controller). The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto Shutdown (ASD) sense - Battery temperature - Battery voltage Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2575 - Ignition circuit sense (ignition switch in ON/OFF/CRANK/RUN position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. Sensor return is a low-noise, low-current, dedicated ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2576 Powertrain Control Module: Description and Operation PCM Operating Modes PCM OPERATING MODES As input signals to the PCM change, the PCM adjusts its response to 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. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. 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 air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch ON (Engine OFF) Mode When the ignition switch activates the fuel injection system, the following actions occur: 1. The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the ignition key is in the "ON" position and the engine is not running (0 rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Engine Start-up Mode This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive the camshaft and crankshaft signal within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequence. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode This is an open loop mode. The PCM adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. Cruise or Idle Mode When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Acceleration Mode Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2577 This is a closed loop mode. The PCM recognizes an increase in throttle position and a decrease in Manifold Vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Deceleration Mode This is a closed loop mode. The PCM recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Wide Open Throttle Mode This is an open mode. The Throttle Position Sensor notifies the PCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 2578 Powertrain Control Module: Service and Repair Fig. 29 - PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel level sensor (fuel gauge sending unit) is located on the fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2582 Fuel Pump Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2583 Fuel Level Sensor: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2584 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR - PCM INPUT The fuel level sensor (fuel gauge sending unit) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multiplexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multiplex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2585 Fuel Level Sensor: Testing and Inspection The fuel level sensor contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the level sensor only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2589 Idle Air Control (IAC) Motor: Locations IAC/MAP/TPS Fig. 25 - IAC Motor Mounting Bolts (Screws) The IAC motor is located on the back of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2590 Idle Air Control Motor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2591 Idle Air Control (IAC) Motor: Description and Operation IDLE AIR CONTROL (IAC) MOTOR - PCM OUTPUT The IAC stepper motor is mounted to the throttle body, and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction, To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: OFF-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the IAC motor through the PCM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2592 Idle Air Control (IAC) Motor: Service and Repair Fig. 25 - IAC Motor Mounting Bolts (Screws) The IAC motor is located on the back of the throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from IAC motor. 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 Information Bus: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 CCD Bus System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2618 Information Bus: Description and Operation CCD BUS (+/-) CIRCUITS - PCM OUTPUTS The Powertrain Control Module (PCM) sends certain output signals through the CCD bus circuits. These signals are used to control certain instrument panel located items and to determine certain identification numbers. ENHANCED ACCIDENT RESPONSE (HIGHLINE CTM ONLY) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. See: Testing and Inspection Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2622 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2623 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2624 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2625 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2626 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2627 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine ...................................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2634 Manifold Absolute Pressure (MAP) Sensor: Locations IAC/MAP/TPS Fig. 26 - MAP Sensor Location The MAP sensor is located on the front of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2635 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2636 Manifold Absolute Pressure (MAP) Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - PCM INPUT The Manifold Absolute Pressure (MAP) sensor is attached to the side of the engine throttle body with 2 screws. The sensor is connected to the throttle body with a rubber L-shaped fitting. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V For a pressure swing of 0 - 15 psi, the voltage changes 4.0 V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor ( TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2637 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 26 - MAP Sensor Location Fig. 27 - MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2638 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2642 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2643 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor 30 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2649 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions Oxygen Sensor: Diagrams California Emissions Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions > Page 2652 Oxygen Sensor: Diagrams Federal Emissions Oxygen Sensor 1/1 Upstream (except California) Oxygen Sensor 1/2 Downstream (except California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2653 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2654 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2655 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S) - PCM INPUT The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. Non-California Engines On certain non-California (Federal) emissions packages, 2 sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Engines On certain California emissions packages, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. OXYGEN SENSOR OPERATION An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7 to 1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heaters/Heater Relays Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used. The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on these engines. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° F - 1100 °F (500 °C - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor (Certain Non-California Emissions) The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined Will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor (Certain Non-California Emissions) The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2656 Downstream Sensors (Certain California Emissions) Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2657 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2658 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Upstream and Downstream Relays are located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2662 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2663 Oxygen Sensor Relay: Diagrams Power Distribution Center Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2664 Oxygen Sensor Upstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2665 Oxygen Sensor Relay: Description and Operation OXYGEN SENSOR HEATER RELAYS - PCM OUTPUT The 2 oxygen (O2) sensor heater relays (upstream and downstream) are located in the Powertrain Distribution Center (PDC). Engines equipped with the California (NAE) Emissions Package use four O2 sensors. Two of the four sensor heater elements (upstream sensors 1/1 and 211) are controlled by the upstream heater relay through output signals from the Powertrain Control Module (PCM). The other two heater elements (downstream sensors 1/2 and 2/2) are controlled by the downstream heater relay through output signals from the PCM. To avoid a large simultaneous current surge, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2666 Oxygen Sensor Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The oxygen sensor heater relays are located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 2676 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up Central Timer Module: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up > Page 2682 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 2683 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Central Timer Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Central Timer Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2731 Central Timer Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation Central Timer Module: Description and Operation System Description and Functional Operation For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2000 DN consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication (CCD Bus) of this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII (R) via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Central Locking Feature - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Remote Radio Switches - Remote Keyless Entry (RKE) - Vehicle Theft Security System (VTSS) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2734 The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for approximately six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Seat belt warning - Malfunction Indicator Lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) - Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini- trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all reset table conditions will be reset. This will occur only if a resettable function (AVG ECO, Trip Odometer, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2735 Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door key cylinder switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned on by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRBIII (R) under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRBIII (R), or customer programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features. The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate (DN) and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRBIII (R). The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the liftgate are equipped with key cylinder mux switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRBIII (R), or by using the customer programming sequence. Through the DRBIII (R), erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Speed Sensitive Intermittent Wipers The DN truck equipped with a highline CTM will utilize speed sensitive intermittent wipers. Only a highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Diagnostics Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2736 The CTM is fully addressable with the DRBIII (R) and it is the recommended method for diagnosis. The CTM reports up to 7 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII (R). The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2737 corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum for 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If the malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal - Logic Capacitor Low - AECM Output Driver Circuit Open - Firing Capacitor Low - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: - Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Shorted to Battery - Driver Squib Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Shorted to Battery - Passenger Squib Shorted to Ground - Warning Lamp Circuit Open/Shorted - No Cluster CCD Message - Cluster Message Mismatch Central Timer Module Diagnostic Trouble Codes Key Cylinder Lock Switch Failure/Lock - Door Lock Switch Failure - Door Unlock Switch Failure - Key Cylinder Lock Switch Failure/Unlock - Wiper Park Switch Failure - EEPROM Checksum Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2738 - Internal ROM Test Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2739 Central Timer Module: Description and Operation Central Timer Module For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 2740 These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2743 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM-CHIME inoperative Chime Inoperative With Any Lamp or Gauge Warning Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2744 Test 1 - 3 SYMPTOM CHIME INOPERATIVE WITH ANY LAMP OR GAUGE WARNING POSSIBLE CAUSES - Open tone request signal circuit - Instrument cluster- chime inoperative with any warning lamp - CTM - Tone request signal circuit Chime Inoperative With Exterior Lights On and Drivers Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2745 Test 1 - 4 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LAMPS ON, DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-CHIME inoperative with headlamp switch - Headlamp switch key in ignition switch sense circuit open - Headlamp switch - key in ignition switch sense open Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2746 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2747 Test 4 - 8 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2748 - Key-in ignition switch sense circuit open Chime Remains On With Ignition On Test 1 - 3 SYMPTOM CHIME REMAINS ON WITH IGNITION ON POSSIBLE CAUSES - Instrument cluster-chime stays ON - Tone request circuit shorted ground - CTM-CHIME stays ON Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2749 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Key-in IGN switch sense circuit shorted ground - Shorted key-in switch - Headlamp switch shorted test, for chime system Doors Lock With Key In Ignition & Front Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2750 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2751 Test 4 - 8 SYMPTOM DOORS LOCK WITH KEY IN IGNITION & FRONT DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2752 - Key-in ignition switch sense circuit open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2753 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2754 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2755 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2756 Central Timer Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2757 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2758 Central Timer Module: Tools and Equipment DRBIII (R) (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2767 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2768 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 2769 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2774 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2775 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2776 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 2777 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2783 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2784 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: Customer Interest PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2789 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2790 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2796 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2797 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2798 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2803 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2804 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2805 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2806 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 2811 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 2812 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool > Page 2817 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM Loss of Communications With Scan Tool > Page 2818 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Powertrain Control Module: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2824 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 2825 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool Powertrain Control Module: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2830 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 2831 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2837 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2838 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8591 > Mar > 00 > Recall Reprogram PCM/Unable to Detect Catalyst Fault > Page 2839 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2844 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2845 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2846 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 8592 > Mar > 00 > Recall Reprogram PCM/Catalyst Faults Go Undetected > Page 2847 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2848 Powertrain Control Module: Specifications Powertrain Control Module Mounting Screws 3 - 5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2849 Powertrain Control Module: Locations Module Locations Powertrain Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2850 Fig. 29 - PCM Location And Mounting The Powertrain Control Module (PCM) is located in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Powertrain Control Module: Connector Views Powertrain Control Module C1 Powertrain Control Module C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Powertrain Control Module C3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Powertrain Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Diagrams/Electrical Diagrams 2000 Dodge JTEC System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description Powertrain Control Module: Description and Operation General Description POWERTRAIN CONTROL MODULE Fig. 1 - PCM Location The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is referred to as JTEC (Jeep/Truck Engine Controller). The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto Shutdown (ASD) sense - Battery temperature - Battery voltage Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2878 - Ignition circuit sense (ignition switch in ON/OFF/CRANK/RUN position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold Absolute Pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system PCM Outputs - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+A) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle Air Control (IAC) motor - Ignition coil - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. Sensor return is a low-noise, low-current, dedicated ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2879 Powertrain Control Module: Description and Operation PCM Operating Modes PCM OPERATING MODES As input signals to the PCM change, the PCM adjusts its response to 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. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. 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 air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch ON (Engine OFF) Mode When the ignition switch activates the fuel injection system, the following actions occur: 1. The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the ignition key is in the "ON" position and the engine is not running (0 rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Engine Start-up Mode This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive the camshaft and crankshaft signal within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequence. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode This is an open loop mode. The PCM adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. Cruise or Idle Mode When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Acceleration Mode Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description > Page 2880 This is a closed loop mode. The PCM recognizes an increase in throttle position and a decrease in Manifold Vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Deceleration Mode This is a closed loop mode. The PCM recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Wide Open Throttle Mode This is an open mode. The Throttle Position Sensor notifies the PCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 2881 Powertrain Control Module: Service and Repair Fig. 29 - PCM Location And Mounting The PCM is located in the engine compartment. REMOVAL To avoid possible voltage spike damage to the PCM, ignition key must be OFF, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3 - 5 Nm (30 - 40 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2885 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2886 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2887 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2888 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2889 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2890 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations Power Distribution Center Oxygen Upstream and Downstream Relays are located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2894 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2895 Oxygen Sensor Relay: Diagrams Power Distribution Center Oxygen Sensor Downstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2896 Oxygen Sensor Upstream Heater Relay (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2897 Oxygen Sensor Relay: Description and Operation OXYGEN SENSOR HEATER RELAYS - PCM OUTPUT The 2 oxygen (O2) sensor heater relays (upstream and downstream) are located in the Powertrain Distribution Center (PDC). Engines equipped with the California (NAE) Emissions Package use four O2 sensors. Two of the four sensor heater elements (upstream sensors 1/1 and 211) are controlled by the upstream heater relay through output signals from the Powertrain Control Module (PCM). The other two heater elements (downstream sensors 1/2 and 2/2) are controlled by the downstream heater relay through output signals from the PCM. To avoid a large simultaneous current surge, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2898 Oxygen Sensor Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The oxygen sensor heater relays are located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2903 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2904 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2905 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2906 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations > Page 2910 Brake Pressure Switch: Description and Operation BRAKE SWITCH - PCM INPUT When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2915 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2916 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2917 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2918 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications Engine Coolant Temperature (ECT) Sensor: Specifications Engine Coolant Temperature Sensor 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations Engine Coolant Temperature (ECT) Sensor: Component Locations Fig. 34 - Engine Coolant Temperature Sensor (Typical) The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Component Locations > Page 2924 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2925 Engine Coolant Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2926 Engine Coolant Temperature (ECT) Sensor: Service Precautions WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2927 Engine Coolant Temperature (ECT) Sensor: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid ON/OFF times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay ON/OFF times (if equipped) - Target idle speed Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Locations > Page 2928 Engine Coolant Temperature (ECT) Sensor: Service and Repair Fig. 34 - Engine Coolant Temperature Sensor (Typical) The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. REMOVAL WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain cooling system. 2. Disconnect electrical connector from sensor. 3. Engines with air conditioning: When removing the connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place the hook part of tool under the connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft. lbs.) torque. 3. Use long needlenose pliers to connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction. 4. Replace any lost engine coolant. Refer to Cooling System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2932 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2933 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2934 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2935 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 2936 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel level sensor (fuel gauge sending unit) is located on the fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2940 Fuel Pump Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2941 Fuel Level Sensor: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2942 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR - PCM INPUT The fuel level sensor (fuel gauge sending unit) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multiplexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multiplex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2943 Fuel Level Sensor: Testing and Inspection The fuel level sensor contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the level sensor only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake Manifold Air Temp. Sensor 28 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2947 Intake Air Temperature (IAT) Sensor: Locations Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The Intake Manifold Air Temperature (IAT) sensor is located in the front/side of the intake manifold. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2948 Intake Air Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2949 Intake Air Temperature (IAT) Sensor: Description and Operation INTAKE MANIFOLD AIR TEMPERATURE SENSOR - PCM INPUT The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2950 Intake Air Temperature (IAT) Sensor: Service and Repair Fig. 36 - Intake Manifold Air Temperature Sensor (Typical) The intake manifold air temperature sensor is located in the front/side of the intake manifold. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications Manifold Absolute Pressure (MAP) Sensor: Specifications MAP Sensor Mounting Screws 3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2954 Manifold Absolute Pressure (MAP) Sensor: Locations IAC/MAP/TPS Fig. 26 - MAP Sensor Location The MAP sensor is located on the front of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2955 Manifold Absolute Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2956 Manifold Absolute Pressure (MAP) Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - PCM INPUT The Manifold Absolute Pressure (MAP) sensor is attached to the side of the engine throttle body with 2 screws. The sensor is connected to the throttle body with a rubber L-shaped fitting. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V For a pressure swing of 0 - 15 psi, the voltage changes 4.0 V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor ( TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2957 Manifold Absolute Pressure (MAP) Sensor: Service and Repair Fig. 26 - MAP Sensor Location Fig. 27 - MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body. 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure (MAP) Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 2958 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations The electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery next to the distributor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2962 Oil Pressure Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 2963 Oil Pressure Sensor: Description and Operation OIL PRESSURE SENSOR - PCM INPUT The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery. The oil pressure sensor uses two circuits. They are: A signal to the PCM relating to engine oil pressure - A sensor ground through the PCM's sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor 30 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location The upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 2969 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions Oxygen Sensor: Diagrams California Emissions Oxygen Sensor 1/1 Upstream (California) Oxygen Sensor 1/2 Downstream (California) Oxygen Sensor 2/1 Upstream (California) Oxygen Sensor 2/2 Downstream (California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > California Emissions > Page 2972 Oxygen Sensor: Diagrams Federal Emissions Oxygen Sensor 1/1 Upstream (except California) Oxygen Sensor 1/2 Downstream (except California) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2973 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2974 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2975 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S) - PCM INPUT The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors. Non-California Engines On certain non-California (Federal) emissions packages, 2 sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Engines On certain California emissions packages, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. OXYGEN SENSOR OPERATION An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7 to 1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heaters/Heater Relays Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used. The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on these engines. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° F - 1100 °F (500 °C - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor (Certain Non-California Emissions) The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined Will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor (Certain Non-California Emissions) The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2976 Downstream Sensors (Certain California Emissions) Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2977 Oxygen Sensor: Service and Repair REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness. Fig. 30 - Upstream Oxygen Sensor (1/1) Location Fig. 31 - Downstream Oxygen Sensor (1/2) Location WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor with an oxygen sensor removal and installation tool. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2978 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2982 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2983 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2984 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2985 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2989 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3014 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE - PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Refer to Odometer and Trip Odometer in Instrument Panel for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3018 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3019 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3020 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3021 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3025 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3031 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3032 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3033 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3034 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3050 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED AND DISTANCE - PCM INPUT Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for fuel system and speed control system operation. Refer to Odometer and Trip Odometer in Instrument Panel for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation BATTERY VOLTAGE - PCM INPUT The battery voltage input provides power to the Powertrain Control Module (PCM). It also informs the PCM what voltage level is supplied to the ignition coil and fuel injectors. If battery voltage is low, the PCM will increase injector pulse width (period of time that the injector is energized). This is done to compensate for the reduced flow through injector caused by the lowered voltage. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications EVAP Canister Purge Solenoid Mounting Bolt 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3059 Canister Purge Solenoid: Locations Fig. 22 - Duty Cycle EVAP Canister Purge Solenoid The Duty Cycle EVAP Canister Purge Solenoid is located at the left-rear side of engine compartment near power brake vacuum unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3060 Proportional Purge Solenoid Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3061 Canister Purge Solenoid: Description and Operation DUTY CYCLE EVAP CANISTER PURGE SOLENOID The duty cycle EVAP canister purge solenoid (DCP) regulates the rate of vapor flow from the EVAP canister to the intake manifold. The Powertrain Control Module (PCM) operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. when de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM cycles (energizes and de-energizes) the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time that the solenoid is energized. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3062 Canister Purge Solenoid: Service and Repair Fig. 22 - Duty Cycle EVAP Canister Purge Solenoid The Duty Cycle EVAP Canister Purge Solenoid is located at the left-rear side of engine compartment near power brake vacuum unit. REMOVAL 1. Disconnect electrical wiring connector at solenoid 2. Disconnect vacuum harness at solenoid. 3. Remove 2 support bracket mounting nuts. 4. Remove solenoid and its support bracket from vehicle. INSTALLATION 1. Position EVAP canister purge solenoid and its mounting bracket. 2. Install mounting nuts and tighten to 8 Nm (75 in. lbs.) torque. 3. Connect vacuum harness and wiring connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications EVAP Canister Mounting Nut 17-24 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3066 Evaporative Emission Control Canister: Locations The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3067 Evaporative Emission Control Canister: Description and Operation Fig. 2 - EVAP Canister Location A maintenance free, EVAP canister is used on all vehicles. The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3068 Evaporative Emission Control Canister: Service and Repair Fig. 21 - EVAP Canister Location The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. REMOVAL 1. Raise vehicle. 2. Disconnect vacuum lines at EVAP canister. Note location of lines before removal. 3. Remove canister mounting nut. 4. Remove canister from mounting bracket. INSTALLATION 1. Position canister locating pins into mounting bracket grommets and install mounting nut. 2. Tighten mounting nut to 17 - 24 Nm (150 - 210 in. lbs.) torque. 3. Connect vacuum lines at canister. 4. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3076 Leak Detection Pump: Specifications Leak Detection Pump (LDP) Mounting Screws 1 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3077 Leak Detection Pump Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3078 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3079 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3080 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3081 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3082 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3083 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3084 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3085 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3086 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3087 Leak Detection Pump: Service and Repair Fig. 24 - Leak Detection Pump (LDP) Location Fig. 25 - LDP Filter Location The LDP is located in the engine compartment under the battery tray and Power Distribution Center (PDC). The LDP filter is attached to the outside of battery tray. The LDP and LDP filter are replaced (serviced) as one unit. REMOVAL 1. Disconnect negative battery cable at battery. 2. Remove battery. 3. Carefully disconnect rubber hose from bottom of LDP filter. 4. Remove clip retaining LDP filter to battery tray and remove filter from tray. 5. Disconnect battery temperature sensor pigtail wiring harness at bottom of battery tray. 6. To gain access to LDP the PDC must be partially removed. Remove PDC-to-fender mounting screw at rear of PDC. Unsnap PDC from battery tray. To prevent damage to PDC wiring, carefully position PDC to gain access to LDP. 7. Remove battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3088 8. Carefully remove vapor/vacuum lines at LDP. 9. Disconnect electrical connector at LDP. Fig. 26 - Leak Detection Pump (LDP) Mounting Screws 10. Remove 3 LDP mounting screws and remove LDP from vehicle. INSTALLATION 1. Install LDP to bottom of battery tray. Tighten screws to 1 Nm (11 in. lbs.) torque. 2. Carefully install vapor/vacuum lines to LDP. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 3. Connect electrical connector to LDP. 4. Install battery tray. 5. Install PDC to fender and battery tray (snaps on to battery tray). 6. Install LDP filter to battery tray (one clip). 7. Install connecting hose to bottom of LDP filter. 8. Connect battery temperature sensor pigtail wiring harness. 9. Install battery. 10. Connect negative battery cable to battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations Fig. 8 Typical Closed Crankcase Ventilation System Fig. 5 PCV Valve/Hose - Typical This system consists of a PCV valve mounted on the cylinder head (valve) cover with a hose extending from the valve to the intake manifold. Another hose connects the opposite cylinder head (valve) cover to the air cleaner housing to provide a source of clean air for the system. A separate crankcase breather/filter is not used. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3093 Positive Crankcase Ventilation Valve: Testing and Inspection Fig. 15 - Vacuum Check At PCV Valve (Typical) 1. With engine idling, remove the PCV valve from cylinder head (valve) cover. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. Also, a strong vacuum should be felt at the valve inlet. Fig. 16 - Vacuum Check At Valve Cover Opening 2. Return the PCV valve into the valve cover. Remove the fitting and air hose at the opposite valve cover. Loosely hold a piece of stiff paper, such as a parts tag, over the opening (rubber grommet) at the valve cover. 3. The paper should be drawn against the opening in the valve cover with noticeable force. This will be after allowing approximately one minute for crankcase pressure to reduce. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3094 Fig. 17 - Shake PCV Valve (Typical) 4. Turn engine off and remove PCV valve from valve cover. The valve should rattle when shaken. 5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. 6. If the paper is not held against the opening in valve cover after new valve is installed, the PCV valve hose may be restricted and must be replaced. The passage in the intake manifold must also be checked and cleaned. 7. To clean the intake manifold fitting, turn a 1/4 inch drill (by hand) through the fitting to dislodge any solid particles. Blow out the fitting with shop air. If necessary, use a smaller drill to avoid removing any metal from the fitting. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3100 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3104 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ........................................................ 500 to 900 rpm Note: Idle speed range achieved by performing Minimum Air Flow Idle Test, using a scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal Bracket Mounting Nuts 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3111 Accelerator Pedal: Service and Repair These engines are equipped with a manual transmission have an additional pedal return spring on the throttle body linkage. REMOVAL CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. Fig. 38 - Accelerator Pedal Removal/Installation 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 38). Plastic cable retainer snaps into pedal arm. 2. Remove two accelerator pedal/bracket nuts (Fig. 38) and remove pedal/bracket assembly from vehicle. INSTALLATION 1. Position pedal/bracket assembly over the two dash panel mounting studs and install retaining nuts. 2. Tighten nuts to 7 Nm (65 in. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3112 Fig. 39 - Index Tab And Slot 3. From inside the vehicle, hold up the accelerator pedal. Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm. The plastic retainer is snapped into the pedal arm. When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm (Fig. 39). Align the index slot (Fig. 39) on the plastic cable retainer to this index tab. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL Housing removal is not necessary for element (filter) replacement. 1. Pry up spring clips from housing cover (spring clips retain cover to housing). Fig. 33 - Air Cleaner Housing Assembly 2. Release housing cover from locating tabs on housing (Fig. 33) and remove cover. 3. Remove air cleaner element (filter) from housing. 4. Clean inside of housing before replacing element. INSTALLATION 1. Install element into housing. 2. Position housing cover into housing locating tabs. 3. Pry up spring clips and lock cover to housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Requirements Fuel: Technical Service Bulletins Fuel - Requirements NUMBER: 14-05-00 GROUP: Fuel DATE: JUNE 9, 2000 MODELS: 2000 (DN) Durango SUBJECT: Premium Fuel (91 Octane) Use Requirement With Durango R/T 5.9L Engine. NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE R/T 5.9L ENGINE. DISCUSSION: The 5.9L engine in the Durango R/T has been calibrated to operate with fuel that is rated at 91 octane or higher (premium fuel). Use of fuel with a lower octane may impact engine performance and durability. NOTE: USE OF FUELS WITH A RATING OF LESS THAN 91 OCTANE WILL CAUSE A SPARK KNOCK CONDITION AND MAY RESULT IN ENGINE DAMAGE. The use of premium or 91 octane fuel is identified on the vehicle in several ways: 1. A yellow and red Premium Fuel Only label is permanently affixed on the inside of the fuel fill door. 2. As a reminder to the dealer, a large temporary label with the words "Attention: Upon Delivery Of This Vehicle To Dealer, Fill Tank With Premium Fuel Only !!!" is affixed to the driver side rear quarter window. 3. In each vehicle, an owner Tips Card will be attached to the inside rear view mirror. It instructs the vehicle operator that 91 octane fuel is required. 4. The Durango R/T Owner Manual instructs the vehicle operator that the 5.9L engine in the R/T model is calibrated for premium grade gasoline. NOTE: PREMIUM FUEL SHOULD BE USED AT ALL TIMES BEGINNING WITH THE A COMPLETE FUEL TANK FILL BY THE DEALER UPON VEHICLE RECEIPT. It is the dealership's responsibility to verify: 1. The Durango R/T 5.9L fuel tank is filled with premium fuel as soon as possible after the receipt of the vehicle from the vehicle shipper. 2. The dealership sales staff is aware of the need for premium fuel use, especially if the vehicle is not prepped immediately after it is received from the vehicle shipper. To assure top performance, the Durango R/T 5.9L vehicle should not be demonstrated until the fuel tank has been filled completely with a good premium grade fuel. 3. The importance of using premium fuel is reviewed with the new vehicle owner at the time of vehicle purchase/delivery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3121 Fuel: Specifications Fuel Rating Fuel Rating Fuel Unleaded fuel having a minimum octane rating of 87. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3122 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation FUEL TANK FILLER TUBE CAP The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Certain models are equipped with a 1/4 turn cap. The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with a California emissions package and a Leak Detection Pump (LDP), the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 3126 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3131 Fuel Pressure Release: Service and Repair Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications Fuel Hose Clamp: Specifications Fuel Hose Clamps (if equipped) 3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 3135 Fuel Hose Clamp: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Specifications > Page 3136 Fuel Hose Clamp: Description and Operation FUEL TUBES/LINES/HOSES AND CLAMPS Also refer to Quick-Connect Fittings. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Resistance 12.0 ohms +/- 1.2 ohms At 20 degrees C (68 degrees F) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3140 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3141 Fuel Injector: Diagrams Fuel Injector No. 1 Fuel Injector No. 2 Fuel Injector No. 3 Fuel Injector No. 4 Fuel Injector No. 5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3142 Fuel Injector No. 6 Fuel Injector No. 7 Fuel Injector No. 8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3143 Fuel Injector: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3144 Fuel Injector: Description and Operation FUEL INJECTORS Fig. 4 - Fuel Injector (Typical) An individual fuel injector is used for each individual cylinder (Fig. 4). The top (fuel entry) end of the injector is attached into an opening on the fuel rail (Fig. 4). The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identity each fuel injector The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector ON and OFF. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. FUEL INJECTORS - PCM OUTPUT The fuel injectors are connected to the engine with the fuel injector rail. The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage (12 volts) is supplied to the injectors through the ASD relay. The ASD relay will shutdown the 12 volt power source to the fuel injectors if the PCM senses the ignition is ON, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds. The PCM determines injector on-time (pulse width) based on various inputs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3145 Fuel Injector: Testing and Inspection To perform a complete test of the fuel injectors and their circuitry, use the DRB III scan tool and refer to the appropriate Powertrain Diagnostics Procedures. To test the injector only, refer to the following: Disconnect the fuel injector wire harness connector from the injector. The injector is equipped with 2 electrical terminals (pins). Place an ohmmeter across the terminals. Resistance reading should be approximately 12 ohms ± 1.2 ohms at 20 °C (68 °F). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3146 Fuel Injector: Service and Repair WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. To remove one or more fuel injectors, fuel rail assembly must be removed from engine. REMOVAL 1. Remove air cleaner assembly. 2. Remove fuel injector rail assembly. Refer to Fuel Injector Rail Removal/Installation. Fig. 32 - Fuel Injector Mounting (Typical) Fig. 33 - Injector Retaining Clips (Typical Injector) 3. Remove clip(s) retaining the injector(s) to fuel rail (Fig. 32) or (Fig. 33). 4. Remove injector(s) from fuel rail. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3147 INSTALLATION 1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly. Refer to Fuel Injector Rail Removal/Installation. 4. Install air cleaner. 5. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions Quick-Connect Fitting: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3151 Quick-Connect Fitting: Description and Operation QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3152 Quick-Connect Fitting: Service and Repair Also refer to Fuel Tubes/Lines/Hoses and Clamps. Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Safety latch clips are used on certain components/lines. Certain fittings may require use of a special tool for disconnection. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: The interior components (O-rings, spacers) of some types of quick-connect fitting are not serviced separately. If service parts are not available, do not attempt to repair a damaged fitting or fuel line. If repair is necessary, replace complete fuel line assembly. 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. Fig. 13 - Single-Tab Type Fitting 4. Single-Tab Type Fitting: This type of fitting is equipped with a single pull tab (Fig. 13). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3153 Fig. 14 - Disconnecting Single-Tab Type Fitting a. Press release tab on side of fitting to release pull tab (Fig. 14). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. b. While pressing release tab on side of fitting, use screwdriver to pry up pull tab (Fig. 14). Fig. 15 - Removing Pull Tab c. Raise pull tab until it separates from quick-connect fitting (Fig. 15). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3154 Fig. 16 - Typical Two-Tab Quick-Connect Fitting 5. Two-Tab Type Fitting: This type of fitting is equipped with tabs located on both sides of fitting (Fig. 16). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 16) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Fig. 17 - Plastic Retainer Ring Type Fitting 6. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 17) usually black in color. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3155 a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (Fig. 17). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring Will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. Fig. 18 - Latch Clip (Type 1) Fig. 19 - Latch Clip (Type 2) 7. Latch Clips: Depending on vehicle model and engine, 2 different types of safety latch clips are used (Fig. 18) or (Fig. 19). Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. a. Type 1: Pry up on latch clip with a screwdriver (Fig. 18). b. Type 2: Separate and unlatch 2 small arms on end of clip and swing away from fuel line (Fig. 19). c. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Quick-Connect Fitting <--> [Fuel Line Coupler] > Component Information > Service Precautions > Page 3156 Fig. 20 - Fuel Line Disconnection Using Special Tool d. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (Fig. 20). Use tool to release locking fingers in end of line. e. With special tool still inserted, pull fuel line from fuel rail. f. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 8. Disconnect quick-connect fitting from fuel system component being serviced. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15 - 30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions Fuel Pressure Regulator: Service Precautions WARNING: - THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. - THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3160 Fuel Pressure Regulator: Description and Operation FUEL FILTER/FUEL PRESSURE REGULATOR Fig. 2 - Fuel Pump Module Components (Typical Pump Module Shown) Fig. 3 - Filter/Regulator (Side View) A combination fuel filter and fuel pressure regulator (Fig. 3) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the Powertrain Control Module (PCM). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3161 The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 3) is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator (Fig. 3). The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump-Description and Operation for more information. Also refer to the Fuel Pressure Leak Down Test and the Fuel Pump Pressure Tests. If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3162 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL FILTER/FUEL PRESSURE REGULATOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. Refer to Fuel System Pressure Release in the Fuel Delivery System. Fig. 22 - Filter/Regulator Location The fuel filter/fuel pressure regulator is located at top of fuel pump module on top of fuel tank (Fig. 22). Fuel pump module removal is not necessary for filter/regulator removal. 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/Installation. 2. Clean area around filter/regulator to prevent contaminants from entering pump module. 3. The fuel filter/regulator is pressed into a rubber grommet. Remove by twisting and pulling straight up. CAUTION: Do not pull filter/regulator more than three inches from fuel pump module. Damage to coiled fuel tube (line) may result. Fig. 23 - Fuel Tube And Clamp (Typical) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 3163 4. Gently cut old fuel tube (line) clamp (Fig. 23) taking care not to damage plastic fuel tube. Remove and discard old fuel tube clamp. 5. Remove plastic fuel tube from filter/regulator by gently pulling downward. Remove filter/regulator from fuel pump module. INSTALLATION 1. Install a new clamp over plastic fuel tube. Fig. 24 - Tightening Fuel Filter Tube Clamp (Typical) 2. Install filter/regulator to fuel tube. Rotate filter/regulator in fuel tube (line) (Fig. 24) until it is pointed towards front of tank (or front of vehicle). 3. Tighten line clamp to fuel line using special Hose Clamp Pliers number C-4124 or equivalent (Fig. 24). Do not use conventional side cutters to tighten this type of clamp. 4. Press filter/regulator (by hand) into rubber grommet. 5. Rotate filter/regulator until pointed towards front of vehicle. 6. Install fuel tank. Refer to Fuel Tank Removal/ Installation. 7. Check for fuel leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3167 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions Fuel Pressure Test Port: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3173 Fuel Pressure Test Port: Testing and Inspection Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 7 - Fuel Pressure Test Gauge (Typical Installation At Test Port) 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 7). The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. tart and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 5. Install protective cap to fuel rail test port. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3177 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3178 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3179 Fuel Pump Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3180 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY - PCM OUTPUT The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3181 Fuel Pump Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 13). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3182 Fuel Pump Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 17). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair Fig. 26 - Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 26). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Mounting Bolts 23 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3189 Fuel Rail: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3190 Fuel Rail: Description and Operation Fig. 5 - Fuel Rail (Typical) The fuel injector rail is used to attach the fuel injectors to the engine. It is mounted to the engine (Fig. 5). High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A fuel pressure test port is located on the fuel rail. A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with a flexible connecting hose. Do not attempt to separate the rail halves at this connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3191 Fuel Rail: Service and Repair WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to Fuel System Pressure Release Procedure. Fig. 29 - Fuel Rail Assembly (Typical) CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connecting hose (Fig. 29). Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to hose. When removing fuel rail assembly for any reason, be careful not to bend or kink connecting hose. REMOVAL 1. Remove negative battery cable at battery. 2. Remove air cleaner. 3. Perform fuel pressure release procedure. 4. Remove throttle body from intake manifold. Refer to Throttle Body removal. Fig. 30 - A/C Compressor Support Bracket (Typical) 5. If equipped with air conditioning, remove A-shaped A/C compressor-to-intake manifold support bracket (three bolts) (Fig. 30). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3192 Fig. 31 - Remove/Install Injector Connector 6. Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 31). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal. 7. Disconnect fuel tube (line) at side of fuel rail, Refer to Quick-Connect Fittings for procedures, 8. Remove remaining fuel rail mounting bolts. 9. Clean dirt/debris from each fuel injector at intake manifold. 10. Gently rock and pull left fuel rail until fuel injectors just start to clear intake manifold. Gently rock and pull right fuel rail until fuel injectors just start to clear intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared intake manifold. 11. Remove fuel rail (with injectors attached) from engine. Fig. 32 - Fuel Injector Mounting (Typical) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3193 Fig. 33 - Injector Retaining Clips (Typical Injector) 12. Remove clip(s) retaining injector(s) to fuel rail (Fig. 32) or (Fig. 33). INSTALLATION 1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Position fuel rail/fuel injector assembly to injector openings on intake manifold. 4. Guide each injector into intake manifold. Be careful not to tear injector O-ring. 5. Push right fuel rail down until fuel injectors have bottomed on injector shoulder. Push left fuel rail down until fuel injectors have bottomed on injector shoulder. 6. Install fuel rail mounting bolts. 7. Connect electrical connector to intake manifold air temperature sensor. 8. Connect electrical connectors at all fuel injectors. To install connector refer to (Fig. 31). Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 9. Install A/C support bracket (if equipped). 10. Install throttle body to intake manifold. Refer to Throttle Body installation. 11. Install fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures. 12. Install air cleaner. 13. Connect battery cable to battery. 14. Start engine and check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Locations Fuel Reservoir: Locations Fuel Pump Module Components (Typical) The fuel reservoir is part of the lower end of the fuel pump module. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Locations > Page 3197 Fuel Reservoir: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Locations > Page 3198 Fuel Reservoir: Description and Operation Fuel Pump Module Components (Typical) FUEL RESERVOIR The fuel reservoir is part of the lower end of the fuel pump module. The reservoir provides fuel at the pump intake under all driving conditions, especially those times when low fuel levels are present. The fuel return line directs fuel into the reservoir. This maintains a full fuel condition in the reservoir even if fuel level is below the reservoir walls. The fuel reservoir is not a serviceable item. It is only serviced with the fuel pump module. Refer to Fuel Pump Module Removal and Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3203 Fuel Gauge Sender: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3204 Fuel Gauge Sender: Description and Operation FUEL GAUGE SENDING UNIT Fig. 2 - Fuel Pump Module Components (Typical Pump Module Shown) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3205 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3206 Fuel Gauge Sender: Service and Repair Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 27). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 4-way electrical connector (Fig. 27). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3207 Fig. 28 - Fuel Gauge Sending Unit Lock Tab/Tracks 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 28). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3211 Idle Air Control (IAC) Motor: Locations IAC/MAP/TPS Fig. 25 - IAC Motor Mounting Bolts (Screws) The IAC motor is located on the back of the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3212 Idle Air Control Motor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3213 Idle Air Control (IAC) Motor: Description and Operation IDLE AIR CONTROL (IAC) MOTOR - PCM OUTPUT The IAC stepper motor is mounted to the throttle body, and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed. At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate. The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling). The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction. To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction, To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place. In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again. When engine rpm is above idle speed, the IAC is used for the following: OFF-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly) - Deceleration air flow control - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages) - Power steering load control The PCM can control polarity of the circuit to control direction of the stepper motor. IAC Stepper Motor Program The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle. Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the IAC motor through the PCM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3214 Idle Air Control (IAC) Motor: Service and Repair Fig. 25 - IAC Motor Mounting Bolts (Screws) The IAC motor is located on the back of the throttle body. REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from IAC motor. 3. Remove two mounting bolts (screws). 4. Remove IAC motor from throttle body. INSTALLATION 1. Install IAC motor to throttle body. 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in. lbs.) torque. 3. Install electrical connector. 4. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3218 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3219 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3220 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3221 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3222 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3223 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Fuel Pump Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3228 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3229 Fuel Pump Relay: Diagrams Power Distribution Center Fuel Pump Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3230 Fuel Pump Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3231 Fuel Pump Relay: Description and Operation FUEL PUMP RELAY - PCM OUTPUT The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3232 Fuel Pump Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 13). - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3233 Fuel Pump Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 17). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Auto Shut Down (ASD) Relay: Locations Power Distribution Center Automatic Shut Down Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3237 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3238 Auto Shut Down (ASD) Relay: Diagrams Power Distribution Center Automatic Shut Down Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3239 Auto Shut Down (ASD) Relay: Service Precautions WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3240 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt+ power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12 + volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. The PCM will sense if or when the ASD relay has been activated through a "sense circuit". Refer to Automatic Shutdown (ASD) Relay Sense - PCM Input for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3241 Auto Shut Down (ASD) Relay: Testing and Inspection Fig. 13 - ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 A and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Auto Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3242 Auto Shut Down (ASD) Relay: Service and Repair Fig. 17 - Power Distribution Center (PDC) Location The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations Rollover Valve: Locations Fig. 1 - Rollover Valve Locations The two rollover valves are used on this vehicle. One is located on top of the fuel pump module and the other is on the top of the fuel tank at the rear. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3246 Rollover Valve: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE ROLLOVER VALVE(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3247 Rollover Valve: Description and Operation Fig. 1 - Rollover Valve Locations The fuel tank is equipped with two rollover valves. The front valve is located on the top of the fuel pump module (Fig. 1). The other valve is located on the top rear of the fuel tank (Fig. 1). The rollover valves will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover, The EVAP canister draws fuel vapors from the fuel tank through these valves. The rear valve cannot be serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation in Fuel System. The front valve can be serviced separately. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Locations > Page 3248 Rollover Valve: Service and Repair Fig. 23 - Rollover Valve Locations Two rollover valves are used. One of the valves permanently mounted to top/rear of fuel tank (Fig. 23). If replacement of this particular valve is necessary, the fuel tank must be replaced. The other rollover valve is located on top of the fuel pump module (Fig. 23). This valve may be serviced separately. Refer to following steps for procedures. REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE ROLLOVER VALVE(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. 1. Disconnect negative battery cable at battery. 2. Remove fuel filler cap and drain fuel tank. 3. Remove fuel tank. 4. Disconnect tube (line) at valve. 5. The rollover valve is seated into a rubber grommet. Remove valve by prying one side upward and then roll valve out of grommet. 6. Discard old grommet. INSTALLATION 1. Install new grommet into fuel pump module. 2. Using finger pressure only, press valve into place. 3. Install fuel tank. Refer to Fuel Tank Installation. 4. Fill fuel tank. Install fuel tank filler cap. 5. Connect negative battery cable. 6. Start vehicle and check for leaks. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3253 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3254 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3255 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3256 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Mounting Bolts 23 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3260 Throttle Body: Locations The throttle body is located on the intake manifold. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3261 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3262 Throttle Body: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 14 - Fixed Orifice Tool A special fixed orifice tool (number 6714) (Fig. 14) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are OFF before performing this test. 2. Shut OFF the engine and remove the air duct at throttle body. Fig. 15 - Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve (Fig. 15). 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve (Fig. 15). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3263 Fig. 16 - Idle Purge Line 5. Disconnect the idle purge vacuum line from fitting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor (Fig. 16). Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. Refer to the appropriate Powertrain Diagnostic Procedures service for DRB operation. 7. Start the engine and allow to warm up. 8. Using the DRB scan tool, scroll through the menus as follows: select-Stand Alone DRB III, select the year 2000 Diagnostics, select-Engine, select-System Test, select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle speed should be 500 - 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. Refer to Throttle Body Removal and Installation. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air duct to throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3264 Throttle Body: Service and Repair A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). REMOVAL 1. Remove the air duct at throttle body. Fig. 18 - Sensor Electrical Connectors (Typical) 2. Disconnect throttle body electrical connectors at MAP sensor, IAC motor and TPS (Fig. 18). 3. Remove vacuum line at throttle body. 4. Remove all control cables from throttle body (lever) arm. Refer to the Accelerator Pedal and Throttle Cable for additional information. Fig. 19 - Throttle Body Mounting Bolts (Typical) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3265 5. Remove four throttle body mounting bolts (Fig. 19). 6. Remove throttle body from intake manifold. 7. Discard old throttle body-to-intake manifold gasket. INSTALLATION 1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle body-to-intake manifold gasket. 3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 Nm (200 in. lbs.) torque. 5. Install control cables. 6. Install vacuum line to throttle body. 7. Install electrical connectors. 8. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal or cables. Fig. 38 - Accelerator Pedal Removal/Installation 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 38). Plastic cable retainer snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. From inside vehicle, pinch both sides of cable housing retainer at dash panel (Fig. 38). Remove cable housing from dash panel and pull into engine compartment. 4. Remove air tube at top of throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3269 Fig. 40 - Throttle Cable At Throttle Body (Typical) 5. Operate throttle body lever (by hand) to full open throttle position. Slip cable end rearward from pin on throttle lever (Fig. 40). Fig. 41 - Cable Release Tab (Typical) 6. Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver (Fig. 41). To prevent cable housing breakage, press on tab only enough to release cable from bracket. Lift cable housing straight up from bracket while pressing on release tab. Remove cable housing. INSTALLATION 1. Snap cable end onto lever pin (Fig. 40). On models with V-8 engines, be sure cable is routed under plastic cam (Fig. 40). 2. Connect cable to throttle body mounting bracket (push down and lock). 3. Install remaining cable housing end into dash panel opening (snaps into position). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3270 Fig. 39 - Index Tab And Slot 4. Install ball end of cable wire through hole in pedal arm. Install plastic cable retainer. The plastic retainer is snapped into pedal arm. When installing the plastic retainer to accelerator pedal arm, note index tab on pedal arm (Fig. 39). Align index slot (Fig. 39) on plastic retainer to this index tab. 5. Operate and test throttle before starting engine. 6. Install air tube to throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position Sensor Mounting Screws 7 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3274 Throttle Position Sensor: Locations IAC/MAP/TPS The TPS is located on the throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3275 Throttle Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3276 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR (TPS) - PCM INPUT The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade. The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - OFF-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3277 Throttle Position Sensor: Service and Repair REMOVAL The TPS is located on side of throttle body. 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. Fig. 21 - TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. INSTALLATION Fig. 22 - Installation (Typical) The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3283 Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 5.2/5.9L V-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3292 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3293 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3294 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3295 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3299 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3300 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3301 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3302 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3303 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Cap Inspection - External - Typical Cap Inspection - Internal - Typical Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Spark Plug Cable Resistance Spark Plug Cable Resistance Minimum 250 ohms at 1 in 3000 ohms at 12 in Maximum 1000 ohms at 1 in 12000 ohms at 12 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3314 Ignition Cable: Service Precautions CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3315 Ignition Cable: Description and Operation Spark plug cables are sometimes referred to as secondary ignition wires. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3316 Ignition Cable: Testing and Inspection Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression~on. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3317 Ignition Cable: Service and Repair Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Manufacturer Diamond Primary Resistance 0.97 - 1.18 ohms at 21 - 27 deg C Secondary Resistance 11,300 - 15,300 ohms at 21 - 27 deg C Toyodenso Primary Resistance 0.95 - 1.20 ohms at 21 - 27 deg C Secondary Resistance 11,300 - 13,300 ohms at 21 - 27 deg C Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3322 Ignition Coil: Mechanical Specifications Ignition Coil Mounting (If Tapped Bolts Are Used) 5 Nm Ignition Coil Mounting (If Nuts/Bolts Are Used) 11 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3323 Ignition Coil: Locations Ignition Coil The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3324 Ignition Coil: Diagrams Ignition Coil Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3325 Ignition Coil: Service Precautions WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION MUST FIRST BE RELIEVED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3326 Ignition Coil: Description and Operation A single ignition coil is used. The coil is not oil filled. The coil windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the coil to be mounted on the engine. The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Battery voltage is supplied to the ignition coil positive terminal from the ASD relay. If the PCM does not see a signal from the crankshaft and camshaft sensors (indicating the ignition key is ON but the engine is not running), it will shut down the ASD circuit. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3327 Ignition Coil: Service and Repair The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same type. REMOVAL Ignition Coil The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head. This bracket is mounted on top of the automatic belt tensioner bracket using common bolts. 1. Disconnect the primary wiring from the ignition coil. 2. Disconnect the secondary spark plug cable from the ignition coil. WARNING: DO NOT REMOVE THE COIL MOUNTING BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS.THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE REMOVED FOR ANY REASON, ALL BELT TENSION MUST FIRST BE RELIEVED. 3. Remove ignition coil from coil mounting bracket (two bolts). INSTALLATION 1. Install the ignition coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 Nm (100 in. lbs.) torque. If the coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 in. lbs.) torque. 2. Connect all wiring to ignition coil. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3333 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3334 Camshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3335 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) Sensor is located in the distributor. The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3336 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor The camshaft position sensor is located in the distributor on all these engines. REMOVAL Distributor removal is not necessary to remove camshaft position sensor. 1. Remove air cleaner assembly. 2. Disconnect negative cable from battery. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor. 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3340 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3341 Crankshaft Position Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3342 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3343 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. CKP Sensor Operation On these engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Specifications > Page 3344 Crankshaft Position Sensor: Service and Repair REMOVAL Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. 1. Remove right front tire and right front wheel- house liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheel-house liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3349 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3350 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3351 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3352 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3353 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 3354 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Plug Type RC12LC4 Electrode Gap 1.01 mm Torque 35 - 41 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3358 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12LC4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3359 Spark Plug: Description and Operation All engines use resistor type spark plugs. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3360 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Normal Operating Normal Operation And Cold (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. On these engines, gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3361 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. Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3362 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. Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3363 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3364 Spark Plug: Service and Repair REMOVAL Heat Shields On these engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. 1. Prior to removing spark plug, spray compressed air around spark plug hole and area around spark plug. This will help prevent foreign material from entering combustion chamber. 2. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. 3. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 4. Inspect spark plug condition. Refer to Spark Plug Conditions. Cleaning The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode fiat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Gap Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3365 Setting Spark Plug Gap-Typical Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3380 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3386 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3387 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 3393 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 3400 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 3401 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3405 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3406 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3407 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3416 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3420 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3424 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3433 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3434 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3435 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3440 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3441 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3442 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3443 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Engine Spark Knock NUMBER: 18-006-03 GROUP: Vehicle Performance DATE: Feb. 28, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-002-01, DATED JAN. 26, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2128 OR HIGHER, AVAILABLE MARCH 17, 2003. SUBJECT: 2000 M.Y Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (EHC), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3449 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Using a Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. Verify that the following NOTES have been reviewed and completed as necessary. 3. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 4. If the only condition experienced is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Connect a battery charger and set as close to a 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3450 NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3451 FAILURE CODE: Could be one or more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-001-01 > Jan > 01 > Engine Performance Enhancements PROM - Programmable Read Only Memory: Customer Interest Engine Performance Enhancements NUMBER: 18-001-01 GROUP: Vehicle Performance DATE: Jan. 26, 2001 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-023-00 REV. A, DATED DEC. 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS LATEST REVISION NOW INCLUDES THE WJ CALIF. EMISSION PACKAGE. SUBJECT: 4.7L Engine Performance Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal20 and 00Cal17) MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: **THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE.** SYMPTOM/CONDITION: Some vehicle engines may exhibit several of the following engine performance conditions: 1. Part throttle or wide open throttle spark knock. 2. **Sag or hesitation following a cold engine start (except WJ with Calif. emissions).** 3. Rough idle. 4. Idle sag when decelerating to a stop. DIAGNOSIS PROCEDURES: 1. If the customer experiences any of the above conditions, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2076 OR HIGHER. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-001-01 > Jan > 01 > Engine Performance Enhancements > Page 3456 REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-001-01 > Jan > 01 > Engine Performance Enhancements > Page 3457 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool PROM - Programmable Read Only Memory: Customer Interest PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3462 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3463 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement Technical Service Bulletin # 21-20-99 Date: 991129 A/T - 46RE Shift Quality/Durability Improvement NUMBER: 21-20-99 GROUP: Transmission EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: 46RE Transmission Shift Quality Improvement for a Drive - Rev - Drive Shift Maneuver OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 and O0Cal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE NOVEMBER 12, 1999 (MDH 1112XX). SYMPTOM/CONDITION: A change has been made to the PCM software to improve the durability of the transmission internal friction components when certain Drive-Reverse-Drive shift maneuvers are attempted. This type of shift maneuver is often associated with, but not limited to, snow plowing activities. The new PCM software improves upon the current engine torque management when the above shift maneuvers are attempted. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3468 Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3469 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code Technical Service Bulletin # 25-02-99 Date: 991129 Catalyst Monitor Does Not Illuminate MIL/Set Fault Code NUMBER: 25-02-99 GROUP: Emissions EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: Catalyst Monitor Does Not Illuminate MIL Or Set A Fault Code OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A SINGLE UPSTREAM OXYGEN SENSOR AND BUILT BEFORE NOVEMBER 1, 1999 (MDH 11O1XX). VEHICLES INVOLVED IN THIS TECHNICAL SERVICE BULLETIN INCLUDE: 1). ALL JEEP AND TRUCK FEDERAL EMISSION PACKAGES (NAA) EXCEPT THE BR/BE WITH A 5.9L OR 8.0L HEAVY DUTY ENGINE. 2). ALL TRUCK CALIFORNIA EMISSION PACKAGES (NAE) EXCEPT THE AN OR THE DN WITH A 4.7L ENGINE, OR THE BR WITH 5.2L AUTO. TRANS OR 5.9L WITH AUTO. TRANS. 3). ONLY JEEP TJ AND XJ CALIFORNIA EMISSION PACKAGES (NAE) WITH A 2.5L ENGINE. SYMPTOM/CONDITION: The vehicle On-Board Diagnostic (OBD) System may not illuminate the Malfunction Indicator Lamp (MIL) or set a Diagnostic Trouble Code (DTC) when a possible problem may have been detected by the catalyst monitor. This condition will most often occur when the technician is in the process of performing powertrain diagnostics. NOTE: ALL APPLICABLE VEHICLES BROUGHT IN FOR ANY MAINTENANCE MAY HAVE THIS FLASH PROCEDURE PERFORMED. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3474 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new sottware part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3475 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3481 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3482 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3483 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3484 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3485 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3486 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3487 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3488 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3489 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3490 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3491 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3492 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3493 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3494 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3495 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3496 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3497 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3498 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3499 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Spark Knock NUMBER: 18-006-03 GROUP: Vehicle Performance DATE: Feb. 28, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-002-01, DATED JAN. 26, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2128 OR HIGHER, AVAILABLE MARCH 17, 2003. SUBJECT: 2000 M.Y Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (EHC), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3504 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Using a Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. Verify that the following NOTES have been reviewed and completed as necessary. 3. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 4. If the only condition experienced is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Connect a battery charger and set as close to a 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3505 NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3506 FAILURE CODE: Could be one or more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Performance Enhancements NUMBER: 18-001-01 GROUP: Vehicle Performance DATE: Jan. 26, 2001 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-023-00 REV. A, DATED DEC. 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS LATEST REVISION NOW INCLUDES THE WJ CALIF. EMISSION PACKAGE. SUBJECT: 4.7L Engine Performance Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal20 and 00Cal17) MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: **THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE.** SYMPTOM/CONDITION: Some vehicle engines may exhibit several of the following engine performance conditions: 1. Part throttle or wide open throttle spark knock. 2. **Sag or hesitation following a cold engine start (except WJ with Calif. emissions).** 3. Rough idle. 4. Idle sag when decelerating to a stop. DIAGNOSIS PROCEDURES: 1. If the customer experiences any of the above conditions, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2076 OR HIGHER. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements > Page 3511 REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements > Page 3512 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3517 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3518 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3519 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3524 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3525 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3526 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3527 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3532 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3533 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement Technical Service Bulletin # 21-20-99 Date: 991129 A/T - 46RE Shift Quality/Durability Improvement NUMBER: 21-20-99 GROUP: Transmission EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: 46RE Transmission Shift Quality Improvement for a Drive - Rev - Drive Shift Maneuver OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 and O0Cal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE NOVEMBER 12, 1999 (MDH 1112XX). SYMPTOM/CONDITION: A change has been made to the PCM software to improve the durability of the transmission internal friction components when certain Drive-Reverse-Drive shift maneuvers are attempted. This type of shift maneuver is often associated with, but not limited to, snow plowing activities. The new PCM software improves upon the current engine torque management when the above shift maneuvers are attempted. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3538 Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3539 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code Technical Service Bulletin # 25-02-99 Date: 991129 Catalyst Monitor Does Not Illuminate MIL/Set Fault Code NUMBER: 25-02-99 GROUP: Emissions EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: Catalyst Monitor Does Not Illuminate MIL Or Set A Fault Code OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A SINGLE UPSTREAM OXYGEN SENSOR AND BUILT BEFORE NOVEMBER 1, 1999 (MDH 11O1XX). VEHICLES INVOLVED IN THIS TECHNICAL SERVICE BULLETIN INCLUDE: 1). ALL JEEP AND TRUCK FEDERAL EMISSION PACKAGES (NAA) EXCEPT THE BR/BE WITH A 5.9L OR 8.0L HEAVY DUTY ENGINE. 2). ALL TRUCK CALIFORNIA EMISSION PACKAGES (NAE) EXCEPT THE AN OR THE DN WITH A 4.7L ENGINE, OR THE BR WITH 5.2L AUTO. TRANS OR 5.9L WITH AUTO. TRANS. 3). ONLY JEEP TJ AND XJ CALIFORNIA EMISSION PACKAGES (NAE) WITH A 2.5L ENGINE. SYMPTOM/CONDITION: The vehicle On-Board Diagnostic (OBD) System may not illuminate the Malfunction Indicator Lamp (MIL) or set a Diagnostic Trouble Code (DTC) when a possible problem may have been detected by the catalyst monitor. This condition will most often occur when the technician is in the process of performing powertrain diagnostics. NOTE: ALL APPLICABLE VEHICLES BROUGHT IN FOR ANY MAINTENANCE MAY HAVE THIS FLASH PROCEDURE PERFORMED. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3544 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new sottware part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3545 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3551 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3552 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3553 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3554 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3555 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3556 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3557 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3558 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3559 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3560 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3561 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3562 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3563 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3564 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3565 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3566 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3567 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3568 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3569 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Spark Knock NUMBER: 18-006-03 GROUP: Vehicle Performance DATE: Feb. 28, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-002-01, DATED JAN. 26, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2128 OR HIGHER, AVAILABLE MARCH 17, 2003. SUBJECT: 2000 M.Y Engine Spark Knock OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (EHC), 5.2L (ELF), OR 5.9L LIGHT DUTY (EML) GASOLINE ENGINE SEE THE TWO TABLES FOR SPECIFIC APPLICATIONS AND EXCLUSIONS. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3574 NOTE: THE FOLLOWING EMISSION PACKAGES ARE NOT APPROVED AND ARE EXCLUDED FROM THIS BULLETIN. THE PCM CALIBRATION OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION INSPECT THE TYPE OF VEHICLE AND ENGINE FOR POSSIBLE EXCLUSION. SYMPTOM/CONDITION: Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load). DIAGNOSIS PROCEDURES: 1. Using a Scan Tool (DRBIII(R) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. Verify that the following NOTES have been reviewed and completed as necessary. 3. Verify that the engine coolant contains a quality antifreeze. The coolant mixture should consist of 44% to 68% antifreeze. 4. If the only condition experienced is the light-to-moderate engine spark knock, then perform the Repair Procedure. NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Connect a battery charger and set as close to a 14 volts charge as possible. 2. Flash the PCM using the TechCONNECT/MDS2 and DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3575 NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 3. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and/or TCM as necessary and cover the label(s) with the clear plastic overlay. 4. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-006-03 > Feb > 03 > Engine Controls - Engine Spark Knock > Page 3576 FAILURE CODE: Could be one or more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Performance Enhancements NUMBER: 18-001-01 GROUP: Vehicle Performance DATE: Jan. 26, 2001 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 18-023-00 REV. A, DATED DEC. 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THIS LATEST REVISION NOW INCLUDES THE WJ CALIF. EMISSION PACKAGE. SUBJECT: 4.7L Engine Performance Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal20 and 00Cal17) MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: **THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 4.7L ENGINE.** SYMPTOM/CONDITION: Some vehicle engines may exhibit several of the following engine performance conditions: 1. Part throttle or wide open throttle spark knock. 2. **Sag or hesitation following a cold engine start (except WJ with Calif. emissions).** 3. Rough idle. 4. Idle sag when decelerating to a stop. DIAGNOSIS PROCEDURES: 1. If the customer experiences any of the above conditions, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2076 OR HIGHER. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements > Page 3581 REPAIR PROCEDURE: 1. Log onto the MDS2 (Mopar Diagnostic System). 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III(R), MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 3. Push the FLASH tab on the MDS2. 4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 6. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 7. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-01 > Jan > 01 > Engine Performance - Enhancements > Page 3582 8. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Loss of Communications With Scan Tool NUMBER: 08-39-99 GROUP: Electrical EFFECTIVE DATE: Dec. 10,1999 SUBJECT: Communications May Stop Between the JTEC PCM and a Generic Scan Tool OVERVIEW: This bulletin involves selectively erasing and reprogramming the JIEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 & OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE NOVEMBER 30, 1999 (MDH 113OXX). SYMPTOM/CONDITION: The JTEC Powertrain Control Module (PCM) may stop communications with a generic scan tool. It may appear that the sensor values are not updating on the generic scan tool screen. This condition may occur at any time during communications between the PCM and Generic Scan Tool. The condition will only occur if a Generic Scan Tool is used to communicate with the PCM, or if the DRB III is used to communicate with the PCM while it is in its generic scan tool mode. If the condition occurs while the DRB III is being used in its generic scan tool mode, a "No Response" message will occur. If the condition occurs, the technician may have to restart initial communications with the PCM in order to continue with their diagnosis. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 Jl962CabIe 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III; THE SYSTEM MUST BE OPERATING AT CIS CD 2047 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to"ON". Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3587 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK"BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "0K" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click update controller software. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-39-99 > Dec > 99 > PCM - Loss of Communications With Scan Tool > Page 3588 Fig. 2 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement Technical Service Bulletin # 21-20-99 Date: 991129 A/T - 46RE Shift Quality/Durability Improvement NUMBER: 21-20-99 GROUP: Transmission EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: 46RE Transmission Shift Quality Improvement for a Drive - Rev - Drive Shift Maneuver OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13 and O0Cal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE NOVEMBER 12, 1999 (MDH 1112XX). SYMPTOM/CONDITION: A change has been made to the PCM software to improve the durability of the transmission internal friction components when certain Drive-Reverse-Drive shift maneuvers are attempted. This type of shift maneuver is often associated with, but not limited to, snow plowing activities. The new PCM software improves upon the current engine torque management when the above shift maneuvers are attempted. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3593 Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-20-99 > Nov > 99 > A/T - 46RE Shift Quality/Durability Improvement > Page 3594 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code Technical Service Bulletin # 25-02-99 Date: 991129 Catalyst Monitor Does Not Illuminate MIL/Set Fault Code NUMBER: 25-02-99 GROUP: Emissions EFFECTIVE DATE: Nov. 29, 1999 SUBJECT: Catalyst Monitor Does Not Illuminate MIL Or Set A Fault Code OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change OOCal13A). MODELS: 2000 (AB) Ram Van 2000 (AN) Dakota 2000 (BR/BE) Ram Truck 2000 (DN) Durango 2000 (TJ) Wrangler 2000 (XJ) Cherokee 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A SINGLE UPSTREAM OXYGEN SENSOR AND BUILT BEFORE NOVEMBER 1, 1999 (MDH 11O1XX). VEHICLES INVOLVED IN THIS TECHNICAL SERVICE BULLETIN INCLUDE: 1). ALL JEEP AND TRUCK FEDERAL EMISSION PACKAGES (NAA) EXCEPT THE BR/BE WITH A 5.9L OR 8.0L HEAVY DUTY ENGINE. 2). ALL TRUCK CALIFORNIA EMISSION PACKAGES (NAE) EXCEPT THE AN OR THE DN WITH A 4.7L ENGINE, OR THE BR WITH 5.2L AUTO. TRANS OR 5.9L WITH AUTO. TRANS. 3). ONLY JEEP TJ AND XJ CALIFORNIA EMISSION PACKAGES (NAE) WITH A 2.5L ENGINE. SYMPTOM/CONDITION: The vehicle On-Board Diagnostic (OBD) System may not illuminate the Malfunction Indicator Lamp (MIL) or set a Diagnostic Trouble Code (DTC) when a possible problem may have been detected by the catalyst monitor. This condition will most often occur when the technician is in the process of performing powertrain diagnostics. NOTE: ALL APPLICABLE VEHICLES BROUGHT IN FOR ANY MAINTENANCE MAY HAVE THIS FLASH PROCEDURE PERFORMED. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3599 1 CH7OOO/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2046 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new sottware part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-99 > Nov > 99 > Catalyst Monitor Does Not Illuminate MIL/Set Fault Code > Page 3600 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3606 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3607 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3608 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3609 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3610 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3611 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3612 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3613 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3614 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3615 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3616 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3617 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3618 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3619 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3620 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3621 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3622 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3623 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3624 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault Technical Service Bulletin # 8591 Date: 000301 Recall - Reprogram PCM/Unable to Detect Catalyst Fault March 2000 Emissions Recall No.8591 (Vehicles Located Out of California) Reprogram PCM - OBD Catalyst Monitor Effective immediately. all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3629 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 Systems Functions 53 and VIP All involved vehicles have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3630 The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8591 > Mar > 00 > Recall - Reprogram PCM/Unable to Detect Catalyst Fault > Page 3631 the VECI label. D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected Technical Service Bulletin # 8592 Date: 000301 Recall - Reprogram PCM/Catalyst Faults Go Undetected March 2000 Emissions Recall No.8592 (Vehicles Located In California) Reprogram PCM - OBD Catalyst Monitor Effective immediately, all repairs on involved vehicles are to be performed according to this recall Technical Service Bulletin (TSB) 25-02-99 is being cancelled. Models 2000 (AB) Dodge Ram Van/Wagon (with a 3.9L, 5.2L or 5.9L engine and sales code NAA or NAE). (AN) Dodge Dakota (with a 2.5L, 3.9L or 5.9L engine and sales code NAA or NAE; or a 4.7L engine and sales code NAA). (BR/BE) Dodge Ram Pickup (with a 3.9L engine and sales code NAA or NAE; 5.2L or 5.9L engine and sales code NAA; or 5.2L or 5.9L engine, manual transmission and sales code NAE). (DN) Dodge Durango (with a 5.2L or 5.9L engine and sales code NAA or NAE; or 4.7L engine and sales code NAA). (TJ) Jeep(R) Wrangler (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). (WJ) Jeep Grand Cherokee (with a 4.OL or 4.7L engine and sales code NAA). (XJ) Jeep Cherokee (with a 2.5L engine and sales code NAA or NAE; or 4.OL engine and sales code NAA). NOTE: This recall applies to the above vehicles equipped with a Federal emission control system (sales code NAA) or California emission control system (sales code NAE) built through October 28, 1999 (MDH102820). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The On-Board Diagnostic (OBD) system on about 309,000 of the previously listed vehicles will not detect a catalyst failure as required by Federal and California regulations. Repair The Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update Labels and Authorized Modifications Labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3636 04275086 Authorized Modifications Label Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the labels 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 Applicable 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 MDS2 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 have been 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 "0RD8591" (vehicles located out of California) or "ORD8592" (vehicles located in California). 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 letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: 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. A. Reprogram the PCM The MDS2 (Mopar Diagnostic System) with the DRB III(R) (Diagnostic Readout Box scan tool) operating at CIS CD2046 or higher is required to perform this repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3637 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MD52 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session. 5. Push the FLASH TAB on the MD52. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says "Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the "OK" button, then continue with Step C. 7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules. record the trouble codes. and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased. B. Install Authorized Software Update Lable Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Lable Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Then attach the label near the VECI label. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3638 D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 8592 > Mar > 00 > Recall - Reprogram PCM/Catalyst Faults Go Undetected > Page 3639 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3654 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3660 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3661 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3675 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3681 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3682 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications 42RE Band adjustment from 72 inch lbs. Front band Back off 3 turns Rear band Back off 4 turns Plug, front band reaction 13 ft.lb Locknut Band Adjust Front Band 25 ft.lb Rear Band 30 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch Clutch: Specifications Direct Clutch Disc Usage 8 Discs ct Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3690 Clutch: Specifications Clutch Pack Clearance Front 3-disc. 0.070 - 0.129 in Clutch Spring Usage 9 Springs Front Clutch Thrust Washer (Reaction Shaft Support Hub) 1st size 0 061 2nd size 0.084 3rd size 0.102 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3691 Clutch: Specifications One-Way Clutch Tightening Specifications Bolt, Overrunning Clutch Cam ............................................................................................................................................................. 17 Nm (13 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3692 Clutch: Specifications Overdrive clutch disc usage 4 discs ct Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 3693 Clutch: Specifications Clutch pack clearance Rear 4-disc. 0.025 - 0.036 in Rear clutch thrust washer (clutch retainer) 0.061 inch Rear clutch pack snap ring 1st size 0.060-0.062 2nd size 0.074-0.076 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 3698 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 3699 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3704 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3705 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3706 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3707 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3708 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3709 Fluid - A/T: Technical Service Bulletins Transmission Fluid Level - Inspection Procedure NUMBER: 21-11-99 GROUP: Transmission DATE: Jul. 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-13-98, DATED OCT. 16, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO THE FLUID/FILTER REPLACEMENT PROCEDURE AND ADDING ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Transmission Fluid Level Inspection Procedure/Service Cautions MODELS: **2000 (AN) Dakota** **2000 (DN) Durango** 1999 - **2000** (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 45RFE TRANSMISSION. DISCUSSION: The 45RFE transmission, **newly introduced in the 1999 model year on Grand Cherokee models and for 2000 Dakota and Durango models, has some unique service features** compared with its predecessors. The following are some items to consider during service: Fluid Level Inspection 1. Warm the fluid to at least 21° C (70° F.) by operating the vehicle. 2. Measure the transmission fluid temperature using the DRB III(R). 3. Move the gear selector through drive and reverse. Place the gear selector in Park. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3710 4. Check the fluid level against the fluid level/temperature chart (Figure 1). NOTE: WHEN COLD (BELOW 10° C {50° F}) THE FLUID LEVEL WILL NOT REGISTER ON THE DIPSTICK. Fluid/Filter Replacement Accurate fluid level is difficult to determine cold. Initially add only 5 quarts of fluid during the refill procedure. **This amount will allow the engine to be started and the transmission to be operated in neutral until the transmission temperature has reached at least 21 C (70° F.)**. Once the fluid temperature is known, the final amount can be added without overfilling the transmission. Additionally, during this procedure, pressure switch and/or loss of prime DTC's may be set. If they are, erase them using the DRB Ill® before returning the vehicle to the customer. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Capacity Model 42RE, 44RE, 46RE ................................................................................................................... ............................................ 9.1-9.5Liters (19-20 Pt) Model 45RFE ....................................................................................................................................... ................................................. 13.33Liters (28.0 Pt) Capacities may vary. Check fluid level on dipstick according to applicable procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3713 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ..................................... Mopar ATF + 4, Type 9602 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3714 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid - A/T: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3717 Fluid - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3718 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3719 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3728 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3734 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 3735 Fluid Filter - A/T: Specifications Screws, fluid filter 35 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Filter - A/T: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3738 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3739 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3740 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair OVERVIEW When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906A Cooler Flusher. CAUTION: The transmission oil cooler requires a two stage flushing procedure due to an internally mounted thermostat. Failure to follow the procedure can result in severe transmission damage. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. COOLER FLUSH USING TOOL 6906A (1) Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. (2) Reinstall filler plug on Tool 6906A. (3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. (5) Connect the BLUE pressure line to the OUTLET (From) cooler line. (6) Connect the CLEAR return line to the INLET (To) cooler line (7) Remove the transmission oil cooler from the vehicle. Refer to Cooling System, for the proper procedures. (8) Remove the transmission oil cooler thermostat. Refer to Cooling System, for the proper procedures. (9) Re-install the thermostat cover onto the oil cooler and install the snap ring. (10) Re-connect the oil cooler to the transmission cooler lines. (11) Turn pump ON for two to three minutes to flush cooler(s) and lines. NOTE: This flushes the bypass circuit of the cooler only. (12) Turn pump OFF. (13) Remove the thermostat cover from the oil cooler. (14) Install Special Tool Cooler Plug 8414 into the transmission oil cooler. (15) Turn pump ON for two to three minutes to flush cooler(s) and lines. NOTE: This flushes the main oil cooler core passages only. (16) Turn pump OFF. (17) Remove the thermostat cover from the oil cooler. (18) Remove Special Tool Cooler Plug 8414 from the transmission oil cooler. (19) Install a new thermostat spring, thermostat, cover, and snap-ring into the transmission oil cooler. (20) Install the transmission oil cooler onto the vehicle. (21) Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. (22) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. (23) Place CLEAR suction line into a one quart container of Mopar ATF +4, type 9602 automatic transmission fluid. (24) Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. (25) Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Torque Specifications Torque Specifications Transmission Component Torque 42RE, 44RE Bolt, Fluid Pan 17 Nm (13 ft. lbs.) 46RE " 17 Nm (13 ft. lbs.) 45RFE " 11.8 Nm (105 in. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Pan: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3749 Fluid Pan: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3750 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 3751 Fluid Pan: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Oil pump gear tip clearance 0.004 - 0.008 in Bolt, Oil Pump 15 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations Governor: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3758 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3759 Governor: Description and Operation GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve generates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device and is located in the governor body on the valve body transfer plate. The inlet side of the solenoid valve is exposed to normal transmission line pressure while in forward gears. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid valve controls governor pressure. One amp current produces 0 psi governor pressure. Zero amps sets the maximum governor pressure. Current is regulated by modulation of the pulse width of a 512 hz driver frequency (512 cycles per second). The powertrain control module (PCM) supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC) and is provided through the battery terminal on the module. The solenoid is polarity sensitive. The PCM energizes the solenoid by grounding it through the power ground terminal on the powertrain control module. GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve. The sensor output signal provides the necessary feedback to the powertrain control module. This feedback is needed to accurately control pressure. The unit is an absolute pressure device and the output is calibrated to be 0.35 to 0.65 volts at 14.7 psi (normal barometric pressure). Since this is an absolute pressure device, 0 psi calibration is required often to compensate for changing atmospheric pressure or altitude. This voltage measured at 0 psi is referred to as zero pressure offset. GOVERNOR SHIFT SCHEDULES The electronic governor has several governor curves possible as opposed to a conventional governor which has a single governor curve with two stages. These transmissions are mechanically and hydraulically the same as the ones they replace. As with all-hydraulic transmissions, the vehicle shift speeds are determined by balancing a hydraulic pressure signal proportional to transmission output speed (called governor pressure) against a pressure signal determined by throttle position (called throttle pressure). The four curves are used during the following operating conditions. Low Transmission Fluid Temperature - When the transmission fluid is cold at or below 30°F the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed. Transfer Case Low-Range Operation - On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares the electronic vehicle speed signal to the transmission output shaft speed signal to determine when the transfer case is in low range. Wide-Open Throttle Operation - In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. Normal Operation - Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load conditions. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. GOVERNOR OPERATION The electronic governor control system replaces the old centrifugal governor pressure control and is located on the valve body. The control system uses a governor pressure solenoid that can vary pressure, a pressure sensor, and the output shaft speed sensor. The electronic governor control system regulates pressure to control shifts in the first three gears. Output shaft and throttle position are used to determine target pressure. Actual governor pressure is read from the sensor and the difference between the target pressure and actual pressure are Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3760 used to determine duty cycle correction. The duty cycle is the amount of time the governor pressure solenoid needs to be OFF to meet the target pressure. Speed of the output shaft, throttle position, controller calculations, and shift lever position determine different governor pressure curves. Governor pressures can be different at the same output shaft speed. The desired pressure is determined by many things including the acceleration of the vehicle. There is no need for concern if at the same output shaft speed there are different requested pressures.There is a need for concern if the target pressure and actual pressure are not within 3 psi for five seconds or more. If this occurs the control system could result in erratic shifting. The only time the governor control system stays at zero is when the gear selector is in park, neutral, reverse or drive with the vehicle at a stop. When the transmission is in park, neutral, or reverse no line pressure is supplied to the governor pressure solenoid making governor pressure zero. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3761 Governor: Service and Repair (1) Hoist and support vehicle on safety stands. (2) Remove transmission fluid pan and filter. Fig. 83 (3) Disengage wire connectors from pressure sensor and solenoid (Fig. 83). (4) Remove screws holding pressure solenoid retainer to governor body. Fig. 84 (5) Separate solenoid retainer from governor (Fig. 84). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Locations > Page 3762 Fig. 85 (6) Pull solenoid from governor body (Fig. 85). (7) Pull pressure sensor from governor body. (8) Remove bolts holding governor body to valve body. Fig. 86 (9) Separate governor body from valve body (Fig. 86). (10) Remove governor body gasket. INSTALLATION Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. (1) Place gasket in position on back of governor body (Fig. 86). (2) Place governor body in position on valve body. (3) Install bolts to hold governor body to valve body. (4) Lubricate O-ring on pressure sensor with transmission fluid. (5) Align pressure sensor to bore in governor body. (6) Push pressure sensor into governor body. (7) Lubricate O-ring, on pressure solenoid, with transmission fluid. (8) Align pressure solenoid to bore in governor body (Fig. 85). (9) Push solenoid into governor body. (10) Place solenoid retainer in position on governor (Fig. 84). (11) Install screws to hold pressure solenoid retainer to governor body. (12) Engage wire connectors into pressure sensor and solenoid (Fig. 83). (13) Install transmission fluid pan and (new) filter. (14) Lower vehicle and road test to verify repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications Input shaft end play 0.034 - 0.084 in Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications Intermediate Shaft: Specifications Dimensional Specifications Intermediate Shaft Spacer ................................................................................................................................................. Select Fit (Refer to Procedure) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Page 3773 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications Dimensional Specifications Thrust Plate (output shaft pilot hub) .................................................................................................... ........................................................... 0.060-0.063 Thrust Washer (Rear Clutch Hub) 1st Size ................................................................................................................................................ .................................................... 0.052 - 0.054 2nd Size ................................................................... ............................................................................................................................... 0.068 - 0.070 3rd Size ...................................................................................................................................................... ............................................. 0.083 - 0.085 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Output Shaft Rear Bearing Output Shaft: Service and Repair Output Shaft Rear Bearing REMOVAL (1) Remove overdrive unit from the vehicle. (2) Remove overdrive geartrain from housing. Fig. 97 (3) Remove snap ring holding output shaft rear bearing into overdrive housing (Fig. 97). (4) Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION (1) Place replacement bearing in position in housing. (2) Using a suitable driver, drive bearing into housing until the snap ring groove is visible. (3) Install snap ring to hold bearing into housing (Fig. 97). (4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Output Shaft Rear Bearing > Page 3779 Output Shaft: Service and Repair Output Shaft Front Bearing REMOVAL (1) Remove overdrive unit from the vehicle. (2) Remove overdrive geartrain from housing. Fig. 98 (3) Remove snap ring holding output shaft front bearing to overdrive geartrain. (Fig. 98). (4) Pull bearing from output shaft. INSTALLATION (1) Place replacement bearing in position on geartrain with locating retainer groove toward the rear. (2) Push bearing onto shaft until the snap ring groove is visible. (3) Install snap ring to hold bearing onto output shaft (Fig. 98). (4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair Output Shaft Bearing/Bushing: Service and Repair REMOVAL (1) Remove overdrive housing yoke seal. Fig. 95 (2) Insert Remover 6957 into overdrive housing. Tighten tool to bushing and remove bushing (Fig. 95). INSTALLATION (1) Align bushing oil hole with oil slot in overdrive housing. (2) Tap bushing into place with Installer 6951 and Handle C-4171. Fig. 96 (3) Install new oil seal in housing using Seal Installer C-3995-A (Fig. 96). OUTPUT SHAFT REAR BEARING REMOVAL (1) Remove overdrive unit from the vehicle. (2) Remove overdrive geartrain from housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair > Page 3783 Fig. 97 (3) Remove snap ring holding output shaft rear bearing into overdrive housing (Fig. 97). (4) Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION (1) Place replacement bearing in position in housing. (2) Using a suitable driver, drive bearing into housing until the snap ring groove is visible. (3) Install snap ring to hold bearing into housing (Fig. 97). (4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications Planetary Gears: Specifications Clearance Specifications Planetary End Play ................................................................................................................................................ 0.127 1.220 mm (0.005 - 0.048 inch) Planetary Geartrain Snap Ring (At Front Of Output Shaft) 1st Size ................................................................................................................................................ .................... 1.4 - 1.5 mm (0.055 - 0.059 inch) 2nd Size .................................................................... ............................................................................................... 1.6 - 1.7 mm (0.062 - 0.066 inch) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T 45RFE Does Not Shift Smoothly > Page 3799 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T 45RFE Does Not Shift Smoothly > Page 3800 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3804 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3805 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3806 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL (1) Raise vehicle. (2) Mark propeller shaft and axle yoke for alignment reference. (3) Disconnect and remove propeller shaft. Fig. 77 (4) Remove old seal with Seal Remover C-3985-B (Fig. 77) from overdrive housing. INSTALLATION (1) Place seal in position on overdrive housing. Fig. 78 (2) Drive seal into overdrive housing with Seal Installer C-3995-A (Fig. 78). (3) Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3817 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3821 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3825 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Service and Repair Shift Interlock: Service and Repair The column shift interlock is used to lock the transmission shifter in the Park position when the key is in the OFF position. The interlock device is located within the steering column assembly and is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair Shift Cable: Service and Repair REMOVAL (1) Shift transmission into Park. Fig. 80 (2) Remove nuts retaining the shift cable housing to the dash panel (Fig. 80). Fig. 81 (3) Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle (Fig. 81). (4) Raise vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 3833 Fig. 82 (5) Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket (Fig. 82). Remove old cable from vehicle. INSTALLATION (1) Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud. (2) Lower vehicle. (3) Route cable through hole in dash panel. Seat cable bracket to dash panel. Install retaining nuts to cable housing bracket studs inside the vehicle at the dash panel. (4) Place the auto transmission manual shift control lever in "Park" detent (rearmost) position and rotate prop shaft to ensure transmission is in park. (5) Connect shift cable to shifter lever by snapping cable retaining ears into shifter bracket and press cable end fitting into lever. (6) Check for proper operation of Park/Neutral switch. (7) If the gearshift cable is out of adjustment, refer to Adjustments. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Stator Shaft, A/T > Component Information > Specifications Stator Shaft: Specifications Tightening Specifications Bolt, Reaction Shaft Support ............................................................................................................... ................................................. 20 Nm (15 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Boost Valve Assembly, A/T <--> [Throttle Valve Assembly, A/T] > Pressure Boost Valve <--> [Throttle Valve, A/T] > Component Information > Locations Pressure Boost Valve: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Bolt, torque convertor 23 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3844 Torque Converter: Description and Operation The torque converter contains a converter clutch mechanism. The converter clutch is an electronically controlled mechanism. It is engaged in fourth gear, and in third gear only when the overdrive control switch is in the OFF position, and also, in third gear over temp mode. The torque converter is not a serviceable component. It should be replaced as an assembly when:diagnosis indicates a malfunction has occurred, or when a major malfunction allows debris to enter the converter. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 3845 Torque Converter: Service and Repair REMOVAL (1) Remove transmission and torque converter from vehicle. (2) Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. (3) Pull the torque converter forward until the center hub clears the oil pump seal. (4) Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. (1) Lubricate oil pump seal lip with transmission fluid. (2) Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. (3) Align torque converter to oil pump seal opening. (4) Insert torque converter hub into oil pump. (5) While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. Fig. 76 (6) Check converter seating with a scale and straightedge (Fig. 76). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. (7) If necessary, temporarily secure converter with C-clamp attached to the converter housing. (8) Install the transmission in the vehicle. (9) Fill the transmission with the recommended fluid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3854 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3860 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 3861 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3865 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3866 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 3867 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Transmission Auxiliary Oil Cooler Bolts 90 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3871 Transmission Cooler: Service and Repair OVERVIEW When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. The only recommended procedure for flushing coolers and lines is to use Tool 6906A Cooler Flusher. CAUTION: The transmission oil cooler requires a two stage flushing procedure due to an internally mounted thermostat. Failure to follow the procedure can result in severe transmission damage. WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES. KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED. KEEP THE AREA WELL VENTILATED. DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK MEDICAL ATTENTION. COOLER FLUSH USING TOOL 6906A (1) Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. (2) Reinstall filler plug on Tool 6906A. (3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. NOTE: The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to remove the drainback valve will prevent reverse flushing the system. A suitable replacement hose can be found in the adapter kit supplied with the flushing tool. (5) Connect the BLUE pressure line to the OUTLET (From) cooler line. (6) Connect the CLEAR return line to the INLET (To) cooler line (7) Remove the transmission oil cooler from the vehicle. Refer to Cooling System, for the proper procedures. (8) Remove the transmission oil cooler thermostat. Refer to Cooling System, for the proper procedures. (9) Re-install the thermostat cover onto the oil cooler and install the snap ring. (10) Re-connect the oil cooler to the transmission cooler lines. (11) Turn pump ON for two to three minutes to flush cooler(s) and lines. NOTE: This flushes the bypass circuit of the cooler only. (12) Turn pump OFF. (13) Remove the thermostat cover from the oil cooler. (14) Install Special Tool Cooler Plug 8414 into the transmission oil cooler. (15) Turn pump ON for two to three minutes to flush cooler(s) and lines. NOTE: This flushes the main oil cooler core passages only. (16) Turn pump OFF. (17) Remove the thermostat cover from the oil cooler. (18) Remove Special Tool Cooler Plug 8414 from the transmission oil cooler. (19) Install a new thermostat spring, thermostat, cover, and snap-ring into the transmission oil cooler. (20) Install the transmission oil cooler onto the vehicle. (21) Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. (22) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. (23) Place CLEAR suction line into a one quart container of Mopar(r) ATF +4, type 9602 automatic transmission fluid. (24) Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. (25) Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Rear Insulator to Bracket Through Bolt 50 ft.lb Rear Insulator to Crossmember Support Bracket 30 ft.lb Transmission Support Bracket Bolts 50 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 3875 Transmission Mount: Service and Repair The content of this article reflects the changes called out by TSB 26-04-00. REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise the vehicle on a hoist. 3. Support the transmission with a jack. Fig. 38 4. Remove engine support bracket and insulator thru-bolt (Fig. 38). 5. Raise the transmission and engine slightly. 6. Remove stud nuts attaching insulator to crossmember. Remove insulator. INSTALLATION 1. If the engine support bracket was removed, position the bracket to the transmission extension. Tighten the bolts to 68 Nm (50 ft. lbs.) torque. 2. Install the insulator onto crossmember. Tighten the stud nuts to 41 Nm (30 ft. lbs) torque. 3. Lower the transmission and engine while aligning the engine support bracket to the insulator. 4. Install thru-bolt in bracket and insulator. Tighten thru-bolt nut to 101 Nm (75 ft. lbs.) torque. 5. Remove transmission jack. 6. Lower the vehicle. 7. Connect the negative cable to the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3879 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3883 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3887 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Valve Body: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3896 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement Valve Body: Customer Interest A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 3901 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-01-00 > Feb > 00 > A/T Harsh Reverse Gear Engagement > Page 3902 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Valve Body: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 3908 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement Valve Body: All Technical Service Bulletins A/T - Harsh Reverse Gear Engagement NUMBER: 21-01-00 GROUP: Transmission DATE: Feb 4, 2000 SUBJECT: Intermittent Harsh Engagement Into Reverse Gear On Certain RE Model Transmissions OVERVIEW: This bulletin involves the replacement of the transmission valve body upper housing separator plate and a valve body check ball. In addition, for 2000 M.Y. vehicles equipped with a 46RE transmission this bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 00Cal13/13A). MODELS: 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 2000 (DN) Durango 1999 - 2000 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO 1999 AND 2000 MODEL YEAR VEHICLES EQUIPPED WITH EITHER A 42RE AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 1, 1999 (MDH 0901 XX) OR 2000 MODEL YEAR VEHICLES EQUIPPED WITH A 46RE AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 1,1999 (MDH I2OIXX). SYMPTOM/CONDITION: The customer may experience a harsh engagement into gear when reverse is selected. This condition may be intermittent, and may occur more frequently as the transmission fluid warms to normal operating temperatures. DIAGNOSIS: 1. Verify that the transmission fluid level is correct. 2. Verify that the valve body throttle valve and transmission shift linkage is adjusted properly. Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2051 OR HIGHER. PARTS REQUIRED: 1 52118261 Ball, Rear Servo Check ('Torlon" - plastic for 42RE and 46RE) 1 52118272 Plate, Valve Body Separator (42RE trans.) 1 04295875 Gasket, Transmission Pan (42RE trans.) 1 04617196AB Plate, Valve Body Separator (46RE trans.) 1 05012978AA Gasket, Transmission Pan (46RE trans.) 10 05010124AA Fluid, Transmission ATF +3 1(AR) 04669020 Label, Authorized Software Update (if a 46RE trans.) 1(AR) 04275086 Label, Authorized Modification (if a 46RE trans.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 3913 REPAIR PROCEDURE: For both the 1999 and 2000 M.Y. 42RE and 46RE Transmission: 1. Refer to the appropriate year information on Transmission and Transfer Case removal and installation instructions of the transmission valve body, check ball, upper housing separator plate, and pan gasket. 2. Replace the original steel rear servo check ball with the plastic "Torlon" check ball (p/n 52118261). 3. Clean the new separator plate to remove any dirt or rust inhibitor prior to installation. 4. Install the new transmission valve body upper housing separator plate (p/n 52118272 or p/n 04617196AB). 5. Reassemble the transmission. 6. Install a new transmission pan gasket (p/n 04295875 or p/n 05012978AA). 7. Lower vehicle and install transmission fluid (p/n 05010124AA). 8. Verify fluid level after warming up the transmission and cycling the shift lever several times. 9. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. For the 2000 M.Y. 46RE Transmission Only: 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III "MESSAGE (ON THE MDS) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM FLASH PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ABS) WITHIN THE VEHICLE IF SO EQUIPPED. SOME MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING FLASHED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-01-00 > Feb > 00 > A/T - Harsh Reverse Gear Engagement > Page 3914 Fig. 1 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Fig. 2 10. Type the necessary information on the "Authorized Modification Label" pin 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-93 Valve Body, Check Ball and Plate - Replace 1.7 Hrs. 1999-2000 (AB, AN, BR, BE, DN, WJ) 08-19-42-94 Powertrain Control Module - Reprogram (46RE only) 0.5 Hrs. 2000 (AN, AB, BR, BE, DN) FAILURE CODE: P8- New Part FM - Flash Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3915 Valve Body: Specifications Bolt, valve body to case 100 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3916 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3917 Transmission Solenoid Assembly Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation OVERVIEW The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. The only replaceable valve body components are: Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter. - Pressure adjusting screw bracket. - Governor pressure solenoid. - Governor pressure sensor (includes transmission temperature thermistor). - Converter clutch/overdrive solenoid assembly and harness. - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL (1) Shift transmission into NEUTRAL. (2) Raise vehicle. (3) Remove gearshift and throttle levers from shaft of valve body manual lever. Fig. 87 (4) Disconnect wires at solenoid case connector (Fig. 87). (5) Position drain pan under transmission oil pan. (6) Remove transmission oil pan and gasket. (7) Remove fluid filter from valve body. (8) Remove bolts attaching valve body to transmission case. (9) Lower valve body enough to remove accumulator piston and springs. (10) Work manual lever shaft and electrical connector out of transmission case. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3920 Fig. 88 (11) Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body (Fig. 88). INSTALLATION Fig. 89 (1) Check condition of O-ring seals on valve body harness connector (Fig. 89). Replace seals on connector body if cut or worn. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3921 Fig. 90 (2) Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket (Fig. 90). Fig. 91 (3) Check condition of seals on accumulator piston (Fig. 91). Install new piston seals, if necessary. (4) Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. (5) Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. (6) Lubricate seal rings on valve body harness connector with petroleum jelly. (7) Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. (8) Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. (9) Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. (10) Then seat valve body in case and install one or two bolts to hold valve body in place. (11) Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. (12) Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. (13) Install throttle and gearshift levers on valve body manual lever shaft. (14) Check and adjust front and rear bands if necessary. (15) Connect solenoid case connector wires. (16) Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. (17) Lower vehicle and fill transmission with Mopar(r) ATF +4, type 9602 fluid. (18) Check and adjust gearshift and throttle valve cables, if necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3922 Valve Body: Service and Repair Disassembly and Assembly Remove the valve body from the transmission. DISASSEMBLY CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. (1) Remove fluid filter. (2) Disconnect wires from governor pressure sensor and solenoid. (3) Remove screws attaching governor body and retainer plate to transfer plate. (4) Remove retainer plate, governor body and gasket from transfer plate. (5) Remove governor pressure sensor from governor body (6) Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. Fig. 99 (7) Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing (Fig. 99). Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Fig. 100 (8) Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate (Fig. 100). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3923 Fig. 101 (9) Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body (Fig. 101). Fig. 102 (10) Remove solenoid and harness assembly from valve body (Fig. 102). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3924 Fig. 103 (11) Remove boost valve cover (Fig. 103). Fig. 104 (12) Remove boost valve retainer, valve spring and boost valve (Fig. 104). Fig. 105 (13) Secure detent ball and spring with Retainer Tool 6583 (Fig. 105). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3925 Fig. 106 (14) Remove park rod E-clip and separate rod from manual lever (Fig. 106). Fig. 107 (15) Remove E-clip and washer that retains throttle lever shaft in manual lever (Fig. 107). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3926 Fig. 108 (16) Remove manual lever and throttle lever (Fig. 108). Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Fig. 109 (17) Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring (Fig. 109). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3927 Fig. 110 (18) Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate (Fig. 110). Hold bracket firmly against spring tension while removing last screw. Fig. 111 (19) Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring (Fig. 111). Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3928 Fig. 112 (20) Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve (Fig. 112). (21) Remove kickdown detent, kickdown valve, and throttle valve and spring (Fig. 112). Fig. 113 (22) Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws (Fig. 113). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3929 Fig. 114 (23) Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring (Fig. 114). Fig. 115 (24) Remove left-side screw and remove 3-4 accumulator housing from valve body (Fig. 115). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3930 Fig. 116 (25) Bend back tabs on boost valve tube brace (Fig. 116). Fig. 117 (26) Remove boost valve connecting tube (Fig. 117). Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Fig. 118 (27) Turn valve body over so lower housing is facing upward (Fig. 118). In this position, the two check balls in upper housing will remain in place and Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3931 not fall out when lower housing and separator plate are removed. (28) Remove screws attaching valve body lower housing to upper housing and transfer plate (Fig. 118). Note position of boost valve tube brace for assembly reference. (29) Remove lower housing and overdrive separator plate from transfer plate (Fig. 118). Fig. 119 (30) Remove the ECE check ball from the transfer plate (Fig. 119). The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Fig. 120 (31) Remove transfer plate from upper housing (Fig. 120). (32) Turn transfer plate over so upper housing separator plate is facing upward. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3932 Fig. 121 (33) Remove upper housing separator plate from transfer plate (Fig. 121). Note position of filter in separator plate for assembly reference. Fig. 122 (34) Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference (Fig. 122). VALVE BODY UPPER HOUSING Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3933 Fig. 123 (1) Note location of check balls in valve body upper housing (Fig. 123). Then remove the one large diameter and the six smaller diameter check balls. Fig. 125 (2) Remove governor plug and shuttle valve covers (Fig. 125). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3934 Fig. 124 (3) Remove E-clip that secures shuttle valve secondary spring on valve stem (Fig. 124). (4) Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides (Fig. 125). (5) Remove boost valve retainer, spring and valve if not previously removed. (6) Remove throttle plug and 1-2 and 2-3 governor plugs (Fig. 112). Fig. 126 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3935 (7) Turn upper housing around and remove limit valve and shift valve covers (Fig. 126). (8) Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing (Fig. 126). (9) Remove 1-2 shift control valve and spring (Fig. 126). (10) Remove 1-2 shift valve and spring (Fig. 126). (11) Remove 2-3 shift valve and spring from valve body (Fig. 126). (12) Remove pressure plug cover (Fig. 126). (13) Remove line pressure plug, sleeve, throttle pressure plug and spring (Fig. 126). VALVE BODY LOWER HOUSING (1) Remove timing valve cover. (2) Remove 3-4 timing valve and spring. (3) Remove 3-4 quick fill valve, spring and plug. (4) Remove 3-4 shift valve and spring. Fig. 127 (5) Remove converter clutch valve, spring and plug (Fig. 127). (6) Remove converter clutch timing valve, retainer and valve spring. 3-4 ACCUMULATOR HOUSING (1) Remove end plate from housing. (2) Remove piston spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3936 Fig. 128 (3) Remove piston. Remove and discard piston seals (Fig. 128). ASSEMBLY CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. LOWER HOUSING (1) Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid (Fig. 127). (2) Install 3-4 timing valve spring and valve in lower housing. (3) Install 3-4 quick fill valve in lower housing. (4) Install 3-4 quick fill valve spring and plug in housing. (5) Install timing valve end plate. Tighten end plate screws to 4 Nm (35 in. lbs.) torque. 3-4 ACCUMULATOR (1) Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid (Fig. 128). (2) Install new seal rings on accumulator piston. (3) Install piston and spring in housing. (4) Install end plate on housing. TRANSFER PLATE Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3937 Fig. 129 (1) Install rear clutch and rear servo check balls in transfer plate (Fig. 129). Fig. 130 (2) Install filter screen in upper housing separator plate (Fig. 130). Fig. 131 (3) Align and position upper housing separator plate on transfer plate (Fig. 131). (4) Install brace plate (Fig. 131). Tighten brace attaching screws to 4 Nm (35 in. lbs.) torque. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3938 (5) Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 in. lbs.) torque. UPPER AND LOWER HOUSING Fig. 132 (1) Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (Fig. 132). Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Fig. 133 (2) Position assembled transfer plate and upper housing separator plate on upper housing (Fig. 133). Be sure filter screen is seated in proper housing recess. (3) Install the ECE check ball into the transfer plate (Fig. 119). The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3939 Fig. 134 (4) Position lower housing separator plate on transfer plate (Fig. 134). Fig. 135 (5) Install lower housing on assembled transfer plate and upper housing (Fig. 135). (6) Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 in. lbs.) torque. Start at center and work out to sides when tightening screws (Fig. 135). UPPER HOUSING VALVE AND PLUG Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3940 Fig. 136 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3941 Fig. 137 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3942 Fig. 138 Refer to (Fig. 136), (Fig. 137) and (Fig. 138) to perform the following steps. (1) Lubricate valves, plugs, springs with clean transmission fluid. (2) Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 in. lbs.) torque. (3) Install 1-2 and 2-3 shift valves and springs. (4) Install 1-2 shift control valve and spring. (5) Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. (6) Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 in. lbs.). (7) Install shuttle valve as follows: (a) Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. (b) Install shuttle valve into housing. (c) Hold shuttle valve in place. (d) Compress secondary spring and install E-clip in groove at end of shuttle valve. (e) Verify that spring and E-clip are properly seated before proceeding. (8) Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 in. lbs.) torque. (9) Install 1-2 and 2-3 valve governor plugs in valve body. (10) Install shuttle valve primary spring and throttle plug. (11) Align and install governor plug cover. Tighten cover screws to 4 Nm (35 in. lbs.) torque. BOOST VALVE TUBE AND BRACE Fig. 139 (1) Position valve body assembly so lower housing is facing upward (Fig. 139). (2) Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. (3) Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port (Fig. 139). (4) Insert and seat each end of tube in housings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3943 Fig. 140 (5) Slide tube brace under tube and into alignment with valve body screw holes (Fig. 140). (6) Install and finger tighten three screws that secure tube brace to valve body housings (Fig. 140). Fig. 141 (7) Bend tube brace tabs up and against tube to hold it in position (Fig. 141). (8) Tighten all valve body housing screws to 4 Nm (35 in. lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. 3-4 ACCUMULATOR Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3944 Fig. 142 (1) Position converter clutch valve and 3-4 shift valve springs in housing (Fig. 142). (2) Loosely attach accumulator housing with right side screw (Fig. 142). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. (3) Install 3-4 shift valve and spring. (4) Install converter clutch timing valve and spring. (5) Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. (6) Swing accumulator housing upward over valve springs and plug. Fig. 143 (7) Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated (Fig. 143). Tighten screws to 4 Nm (35 in. lbs.). VALVE BODY FINAL (1) Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 in. lbs.) torque. (2) Insert manual lever detent spring in upper housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3945 Fig. 144 (3) Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (Fig. 144). (4) Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. (5) Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. (6) Then install manual lever seal, washer and E-clip. Fig. 145 (7) Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve (Fig. 145). (8) Position line pressure adjusting screw in adjusting screw bracket. (9) Install spring on end of line pressure regulator valve. (10) Install switch valve spring on tang at end of adjusting screw bracket. (11) Install manual valve. (12) Install throttle valve and spring. (13) Install kickdown valve and detent. (14) Install pressure regulator valve. (15) Install switch valve. (16) Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 in. lbs.) torque. (17) Perform Line Pressure and Throttle Pressure adjustments. Refer to Adjustment for proper procedures. (18) Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 3946 Fig. 146 (19) Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing (Fig. 146). Seat tang in dimple before tightening connector screw. (20) Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 in. lbs.) torque. Fig. 147 (21) Verify that solenoid wire harness is properly routed (Fig. 147). Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. GOVERNOR BODY, SENSOR AND SOLENOID (1) Turn valve body assembly over so accumulator side of transfer plate is facing down. (2) Install new O-rings on governor pressure solenoid and sensor. (3) Lubricate solenoid and sensor O-rings with clean transmission fluid. (4) Install governor pressure sensor in governor body. (5) Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. (6) Position governor body gasket on transfer plate. (7) Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. (8) Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 in. lbs.) torque. (9) Connect harness wires to governor pressure solenoid and governor pressure sensor. (10) Install fluid filter and pan. (11) Lower vehicle. (12) Fill transmission with recommended fluid and road test vehicle to verify repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Differential Cover: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid Fluid - Differential: Technical Service Bulletins Differential Cover - Updated Sealer & Fluid NUMBER: 03-08-00 GROUP: Axle & Propeller Shaft DATE: Sep. 5, 2000 SUBJECT: RTV Use On Corporate Axle MODELS: NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH AN 8.25, 9.25, OR C205F CORPORATE AXLE. DISCUSSION: The axle lubricant used in all corporate axles was changed in formulation starting at the beginning of the 1998 model year. The corporate axles involved include: the 8.25 and 9.25 rear axles, and the C205F front axle. The new lubricant in use is SAE 75W-90 p/n 05010320AA. The lubricant change was made as a fuel economy improvement. The new axle lubricant is more chemically aggressive/reactive when in contact with the previous used Room Temperature Vulcanizable (RTV) sealant. Because of this condition, the RTV used in assembly of the pan/cover to the axle housing was revised and improved. When re-sealing axle covers, using the proper sealing material to minimize any potential sealant breakdown is important. The only recommended sealing material for all corporate axle covers is MOPAR RTV Sealant, p/n 05013477M. This RTV is red/orange in color. NOTE: IF SAE 75W-90 LUBRICANT IS USED TO REFILL ANY CORPORATE AXLE, THEN THE RED/ORANGE MOPAR RTV SEALANT, P/N 05013477AA, SHOULD BE USED TO SEAL THE COVER TO THE AXLE HOUSING. To optimize sealant performance and enhance adhesion, flanges should be clean and free of residual lubricant. The mating flanges should first be cleaned of any excess old RTV using a plastic putty knife. Final cleaning/degreasing shall be done by spraying MOPAR Brake Parts Cleaner, p/n 04549623, on the carrier and cover flanges, followed by a wipe with a clean dry cloth. Care should be taken to avoid spraying the parts cleaner inside the carrier. Once the RTV has been applied, the axle cover is to be installed to the housing within 3 to 5 minutes to prevent skinning over of the RTV. NOTE: IF THE AXLE COVER IS NOT INSTALLED WITHIN THE 3 TO 5 MINUTE TIME FRAME, THE CARRIER COVER FACE MUST BE RECLEANED AND NEW RTV APPLIED, OR ADHESION QUALITY WILL BE COMPROMISED. Immediately install the cover attaching bolts and tighten them to the specified torque to prevent a shimming effect by the RTV. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Differential Cover - Updated Sealer & Fluid > Page 3956 Fluid - Differential: Technical Service Bulletins Differential - Fluid Discoloration Explanation NUMBER: 03-02-00 GROUP: Axles DATE: Mar.03, 2000 SUBJECT: 9.25 Axle Gear Marking Compound Causes A Milky-Like Appearance To The Axle Fluid MODELS: 1999 - 2000 (AB) Ram Van 1999 - 2000 (AN) Dakota 1999 - 2000 (BR/BE) Ram Truck 1999 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 9.25 INCH REAR AXLE AND BUILT BETWEEN NOV. 1, 1998 (MDH 1101XX) AND NOV. 1,1999 (MDH 1101XX). DISCUSSION: The customer or servicing technician may notice a milky-like appearance to the 9.25 inch rear axle fluid. This condition may be brought to the customer's attention when the axle fluid is inspected during normal service. Other than the concern for the color of axle fluid, the customer does not experience any other axle complaint. The customer or servicing technician may be concerned because a milky-like appearance to the axle fluid may also indicate the presence of water. The cause of the milky-like appearance to the axle fluid may be due to the use of a white color gear marking compound during the axle assembly process. Axle gear marking compound is used to verify correct ring and pinion gear alignment during manufacture. The 9.25 inch rear axle is assembled on two different assembly lines. To visually distinguish axles from each assembly line, one assembly line used a white color gear marking compound (versus yellow). Half of the axles that were assembled during the above time frame may have the white gear marking compound mixed with the rear axle fluid. The white color gear marking compound is no longer in use by the axle assembly plant. NOTE: IF THE MILKY-LIKE REAR AXLE FLUID APPEARANCE IS DUE TO THE WHITE GEAR MARKING COMPOUND, THEN NO SERVICE ACTION IS NECESSARY TO ADDRESS THIS CONDITION. If the milky-like rear axle fluid appearance is due to the presence of water, then the rear axle will require service. Axle fluid, contaminated with water, may cause rust and damage to the internal components of the axle. Any water in the axle fluid will begin to boil off (reach its gaseous state) before the oil. Placing a small sample of axle fluid on a hot steel surface (around 100C or 212F) will cause any water that may be present in the fluid to boil off with a "sizzle-like" sound. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DIFFERENTIAL FLUID CAPACITY C205F .................................................................................................................................................. .................................................... 1.66Liters (3.5 pts) 8 1/4 AA ............................................................................................................................................... ................................................... 2.22Liters (4.7 pts) With Trac-Lok include 5.0 oz of friction modifier 9 1/4 ..................................................................................................................................................... .................................................... 2.32Liters (4.9 pts) With Trac-Lok include 5.0 oz of friction modifier Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3959 Fluid - Differential: Fluid Type Specifications Rear Differential 8 1/4" ................................................................................................................................................... ......................................... Thermally Stable 80W-90 9 1/4" ................................................................ ............................................................................................................................ Thermally Stable 75W-90 Note: Vehicles equipped with Trac-Lok limited slip differential requires use of friction modifier. Front Differential Thermally Stable 80W-90. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 3960 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Description and Operation > Rear Axle - 8 1/4 Fluid - Differential: Description and Operation Rear Axle - 8 1/4 DESCRIPTION Multi-purpose, hypoid gear lubricant should be used for rear axles with a standard differential. The lubricant should have a MIL-L-2105C and API GL 5 quality specifications. Trac-Lok differentials require the addition of 5 oz. of friction modifier to the axle lubricant after service. The 8 1/4 axle lubricant capacity is 2.22 L (4.7 pts.) total, including the friction modifier, if necessary. The 9 1/4 axle lubricant capacity is 2.32 L (4.9 pts.) total, including friction modifier, if necessary. NOTE: If the rear axle is submerged in water, the lubricant must be replaced immediately. Avoid the possibility of premature axle failure resulting from water contamination of the lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Description and Operation > Rear Axle - 8 1/4 > Page 3963 Fluid - Differential: Description and Operation Rear Axle - 9 1/4 DESCRIPTION Multi-purpose, hypoid gear lubricant should be used for rear axles with a standard differential. The lubricant should have a MIL-L-2105C and API GL 5 quality specifications. Trac-Lok differentials require the addition of 5 oz. of friction modifier to the axle lubricant after service. The 8 1/4 axle lubricant capacity is 2.22 L (4.7 pts.) total, including the friction modifier, if necessary. The 9 1/4 axle lubricant capacity is 2.32 L (4.9 pts.) total, including friction modifier, if necessary. NOTE: If the rear axle is submerged in water, the lubricant must be replaced immediately. Avoid the possibility of premature axle failure resulting from water contamination of the lubricant. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Description and Operation > Page 3964 Fluid - Differential: Service and Repair (1) Raise and support the vehicle. (2) Remove the lubricant fill hole plug from the differential housing cover. (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning. (5) Remove the original sealant from the housing and cover surfaces. Fig. 9 (6) Apply a bead of Mopar(r) Silicone Rubber Sealant, or equivalent, to the housing cover (Fig. 9). Install the housing cover within 5 minutes after applying the sealant. (7) Install the cover and any identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. (8) For Trac-lok (r) differentials, a quantity of Mopar(r) Trac-lok(r) lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. Refer to the Specifications for the quantity necessary. (9) Fill differential with Mopar(r) Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. Refer to Specifications for the quantity necessary. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. (10) Install the fill hole plug and lower the vehicle. (11) Trac-lok(r) differential equipped vehicles should be road tested by making 10 to 12 slow figure eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Rear Axle - 8 1/4 Pinion Bearing: Specifications Pinion Bearing Preload Original 10 - 20 in.lb New 15 - 35 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Rear Axle - 8 1/4 > Page 3969 Pinion Bearing: Specifications Pinion Bearing Preload Original 10 - 20 in.lb New 15 - 35 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair Pinion Gear: Service and Repair NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear. REMOVAL (1) Remove differential from the axle housing. (2) Mark the companion flange and propeller shaft for installation alignment. (3) Disconnect the propeller shaft from the companion Range. Using suitable wire, tie propeller shaft to underbody. (4) Install socket head bolts into two of the threaded holes in the companion flange, 180° apart. (5) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange. (6) Use Holder 6719 to hold companion flange and remove the companion flange nut and washer. Fig. 27 (7) Using Remover C-452, remove the companion flange from the pinion (Fig. 27). (8) Partially install pinion nut onto pinion to protect the threads. Fig. 28 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3973 (9) Remove the pinion from housing (Fig. 28). Catch the pinion with your hand to prevent it from falling and being damaged. (10) Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. (11) Remove oil slinger, if equipped, and front pinion bearing. (12) Remove the front pinion bearing cup with: Fig. 29 - Remover C-4345 and Handle C-4171 for the 8 1/4 axles (Fig. 29). - Bearing Removal Tool Set 6310 and Adapter - Foot 6310-9 for the 9 1/4 axles. Fig. 30 (13) Remove the rear bearing cup from housing (Fig. 30). Use: - Remover C-4307 and Handle C-4171 for the 8 1/4 axle. - Remover C-4309 and Handle C-4171 for the 9 1/4 axle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3974 Fig. 31 (14) Remove the collapsible preload spacer (Fig. 31). Fig. 32 (15) Remove the rear bearing from the pinion (Fig. 32) with: - Puller/Press C-293-PA and Adapters C-293-47 for the 8 1/4 axle. - Puller/Press C-293-PA and Adapters C-293-37 for the 9 1/4 axle. Place 4 adapter blocks so they do not damage the bearing cage. (16) Remove the depth shims from the pinion shaft. Record the thickness of the depth shims. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3975 (1) Apply Mopar(r) Door Ease, or equivalent stick lubricant to outside surface of bearing cup. Fig. 33 (2) Install the pinion rear bearing cup (Fig. 33) with: - Installer C-4308 and Driver Handle C-4171 for the 8 1/4 axle. - Installer C-4310 and Driver Handle C-4171 for the 9 1/4 axle. (2) Ensure cup is correctly seated. (3) Apply Mopar(r) Door Ease, or equivalent stick lubricant to outside surface of bearing cup. Fig. 34 (4) Install the pinion front bearing cup (Fig. 34) with: - Installer D-130 and Handle C-4171 for the 8 1/4 axle. - Installer D-129 and Handle C-4171 for the 9 1/4 axle. (5) Install pinion front bearing, and oil slinger, if equipped. (6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3976 Fig. 35 - Installer C-4076-B and Handle C-4735-1 for the 8 1/4 axle (Fig. 35). - Installer C-3860-A and Handle C-4171 for the 9 1/4 axle. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion head to achieve proper ring gear and pinion mesh. If the factory installed ring gear and pinion are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. (7) Place the proper thickness depth shim on the pinion shaft. Fig. 36 (8) Install the rear bearing and slinger, if equipped, on the pinion (Fig. 36) with: - Installer 6448 for the 8 1/4 axle. - Installer C-3095 for the 9 1/4 axle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3977 Fig. 37 (9) Install a new collapsible preload spacer on pinion shaft and install the pinion in the housing (Fig. 37). (10) Install the pinion in housing. (11) Install the companion flange with Installer C-3718 and Holder 6719. (12) Install socket head bolts into two of the threaded holes in the companion Range, 180° apart. (13) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange. (14) Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing endplay if a new collapsible spacer was installed. Fig. 38 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 3978 (15) Tighten the nut to 285 Nm (210 ft. lbs.) (Fig. 38). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. (16) Using Holder 6719, crush collapsible spacer until bearing end play is taken up. Fig. 39 (17) Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 39). (18) Check bearing rotating torque with an inch pound torque wrench (Fig. 39). The torque necessary to rotate the pinion should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). (19) Install propeller shaft. (20) Install differential in housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair Ring Gear: Service and Repair NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the ring gear without replacing the pinion. REMOVAL (1) Remove differential from axle housing. Fig. 25 (2) Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 25). (3) Remove bolts holding ring gear to differential case. (4) Using a soft hammer, drive ring gear from differential case (Fig. 25). (5) Use a brass drift and slowly tap the exciter ring from the differential case. INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. (1) Invert the differential case. (2) Position exciter ring on differential case. (3) Using a brass drift, slowly and evenly tap the exciter ring into position. (4) Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (5) Invert the differential case in the vise. (6) Install new ring gear bolts and alternately tighten to: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Page 3982 Fig. 26 - 102 Nm (75 ft. lbs.) torque (Fig. 26) for 8 1/4 axles. - 157 Nm (115 ft. lbs.) torque (Fig. 26) for 9 1/4 axles. (7) Install differential in axle housing and verify gear mesh and contact pattern. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL (1) Raise and support the vehicle. (2) Scribe a mark on the universal joint, companion flange, and pinion shaft for installation reference. (3) Disconnect the propeller shaft from the companion flange. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. (4) Remove the wheel and tire assemblies. (5) Remove the brake drums to prevent any drag. The drag may cause a false bearing preload torque measurement. (6) Rotate the companion flange three or four times. (7) Measure the amount of torque necessary to rotate the pinion with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. (8) Install socket head bolts into two of the threaded holes in the companion flange, 180° apart. (9) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange. (10) Hold the flange with Holder 6719. Remove the pinion nut and washer. Fig. 15 (11) Remove the companion flange with Remover C-452 (Fig. 15). (12) Remove the pinion seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION (1) Clean the seal contact surface in the housing bore. (2) Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft. (3) Inspect companion flange for cracks, worn splines and worn seal contact surface. Replace companion flange if necessary. NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. (4) Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 3986 Fig. 16 (5) Install the new pinion seal with Installer C-4076-B and Handle C-4735-1 for 8 1/4 axles (Fig. 16) and Installer C-3860-A and Handle C-4171 for 9 1/4 axles. NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing. (6) Position the companion flange on the end of the shaft with the reference marks aligned. (7) Install socket head bolts into two of the threaded holes in the companion flange, 180° apart. (8) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange. (9) Seat companion flange on pinion shaft with Installer C-3718 and Holder 6719. (10) Remove the Installer C-3718 and install the pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result. Fig. 17 (11) Hold companion flange with Holder 6719 and tighten the pinion nut to 285 Nm (210 ft. lbs.) (Fig. 17). Rotate pinion several revolutions to ensure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 3987 the bearing rollers are seated. Fig. 18 (12) Rotate the pinion using an (inch lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.) (Fig. 18). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. The torque sequence will then have to be repeated. (13) If the rotating torque is low, use Holder 6719 to hold the companion flange (Fig. 17) and tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this Indicates a binding condition. (14) The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). (15) Install the propeller shaft with the installation reference marks aligned. (16) Tighten the companion flange bolts to 108 Nm (80 ft. lbs.). (17) Install the brake drums. (18) Install wheel and tire assemblies and lower the vehicle. (19) Check the differential housing lubricant level, Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference Axle Shaft: Service and Repair Dana Axle Number Cross Reference New Model Number ............................................................................................................................. ..................................... Old Dana Model Number 174 ....................................................................................................................................................... .......................................................................... 28 181 ....................................................................... .......................................................................................................................................................... 30 186 .................................................................................................................................................. .................................................................... Super 30 194 .................................................................. .............................................................................................................................................................. . 35 198 ................................................................................................................................................ ...................................................................... Super 35 200 ................................................................ .............................................................................................................................................................. ... 36 216 .............................................................................................................................................. ................................................................................... 44 226 .............................................................. ........................................................................................................................................................ Super 44 229 ....................................................................................................................................... .......................................................................................... 50 248 ....................................................... .............................................................................................................................................................. ............ 60 267 ..................................................................................................................................... ............................................................................................ 70 286 ..................................................... .............................................................................................................................................................. .............. 80 First Letter of Suffix F .......................................................................................................................................................... ................................................................ Front R ................................................................................ ........................................................................................................................................... Rear Second Letter of Suffix B .......................................................................................................................................................... ................................................................ Beam I ................................................................................ ................................................................................................................................ Independent Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3994 Third Letter of Suffix I ............................................................................................................................................................ ................................................................. Iron A ................................................................................. ................................................................................................................................. Aluminum Examples: 248FBI ................................................................................................................................................. ................... Dana 60, Front, Beam Axle, Iron 186FIA .............................................................................................................................................. Dana Super 30, Front, Independent, Aluminum 226RBA ............................................................................................................................................... Dana Super 44, Rear, Beam Axle, Aluminum Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3995 Axle Shaft: Service and Repair Rear Axle - 8 1/4 and 9 1/4 REMOVAL (1) Raise and support vehicle. Ensure that the transmission is in neutral. (2) Remove wheel and tire assembly. (3) Remove brake drum. Refer to Brakes and Traction Control, for proper procedure. (4) Clean all foreign material from housing cover area. (5) Loosen housing cover bolts. Drain lubricant from the housing and axle tubes. Remove housing cover. Fig. 10 (6) Rotate differential case so that pinion mate shaft lock screw is accessible. Remove lock screw and pinion mate shaft from differential case (Fig. 10). Fig. 11 (7) Push axle shaft inward and remove axle shaft C-lock from the axle shaft (Fig. 11). (8) Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle tube. (9) Inspect axle shaft seal for leakage or damage. (10) Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced. INSTALLATION (1) Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. (2) Insert C-lock in end of axle shaft. Push axle shaft outward to seat C-lock in side gear. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana Axle Number Cross Reference > Page 3996 (3) Insert pinion shaft into differential case and through thrust washers and differential pinions. (4) Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.) torque. (5) Install cover and add fluid. Refer to Specifications for lubricant requirements. (6) Install brake drum. Refer to Brakes and Traction Control, for proper procedures. (7) Install wheel and tire. (8) Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL (1) Remove axle shaft. Fig. 12 (2) Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 12). NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. Fig. 13 (3) Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9 (Fig. 13). INSTALLATION NOTE: Do not install the original axle shaft seal. Always install a new seal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 4000 (1) Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Fig. 14 (2) Install the axle shaft bearing with Installer C-4198 and Handle C-4171 (Fig. 14). Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. (3) Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. (4) Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. (5) Install the axle shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4005 Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Wheel Hub, Service and Repair for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4008 Wheel Bearing: Service and Repair Rear For further information regarding this component and the system it is a part of, refer to Axle Shaft, Conventional Fixed/Floating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments Center Support: Adjustments Drive away shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. The decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments > Page 4017 Center Support: Service and Repair REMOVAL (1) Remove rear propeller shaft. (2) Remove slip joint boot clamp and separate the two half-shafts. (3) Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. (4) Position Bearing Splitter Tool 1130 between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. (5) Set shaft in press and press bearing off the shaft. INSTALLATION (1) Install new slinger on shaft and drive into position with appropriate installer tool. (2) Install new center bearing on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. (3) Clean shaft splines and apply a coat of multipurpose grease. (4) Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp. (5) Install propeller shaft in vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft Drive/Propeller Shaft: Description and Operation Propeller Shaft DESCRIPTION Fig. 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft > Page 4022 Fig. 3 Fig. 4 A propeller shaft (Fig. 2), (Fig. 3), and (Fig. 4) is the shaft which connects the transmission/transfer case to the axle differential. This is the link through which the engine power is transmitted to the axle. The propeller shaft is designed and built with the yoke lugs in line with each other which is called zero phasing. This design produces the smoothest running condition, an out-of-phase shaft can cause a vibration. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. PRECAUTIONS Use the exact replacement parts when installing the propeller shafts. The use of the correct replacement parts helps to ensure safe operation. All fasteners must be torqued to the specified values for safe operation. Fig. 1 Also make alignment reference marks (Fig. 1) on the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possible vibration. CAUTION: Do not allow the propeller shaft to drop or hang from any propeller shaft joint during removal. Attach the propeller shaft to the vehicle underside with wire to prevent damage to the joints. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft > Page 4023 OPERATION The propeller shaft must operate through constantly changing relative angles between the transmission and axle. It must also be capable of changing length while transmitting torque. The axle rides suspended by springs in a floating motion. The propeller shaft must be able to change operating angles when going over various road surfaces. This is accomplished through universal joints, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion (Fig. 2), (Fig. 3), and (Fig. 4). Before undercoating a vehicle, the propeller shaft and the U-joints should be covered to prevent an out-of-balance condition and driveline vibration. CAUTION: Use original equipment replacement parts for attaching the propeller shafts. The specified torque must always be applied when tightening the fasteners. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft > Page 4024 Drive/Propeller Shaft: Description and Operation Center Bearing DESCRIPTION Vehicles equipped with a two-piece propeller shaft uses a rubber insulated center bearing. The bearing is used to support the shafts where they are joined together. OPERATION The propeller shaft center bearing serves to divide the required propeller shaft length into two smaller shafts, which has several inherent advantages. Having two short propeller shafts instead of one long shaft decreases the chance of unwanted noise and vibrations. The shorter shafts are easier to balance and serve to increase ground clearance while maintaining acceptable driveline angles. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft > Page 4025 Drive/Propeller Shaft: Description and Operation Propeller Shaft Joints DESCRIPTION Fig. 5 Fig. 6 Two different types of propeller shaft joints are used in AN vehicles (Fig. 5) and (Fig. 6). None of the joints are serviceable. If worn or damaged, they must be replaced as a complete assembly. LUBRICATION The factory installed universal joints are lubricated for the life of the vehicle and do not need lubrication. All universal joints should be inspected for leakage and damage each time the vehicle is serviced. If seal leakage or damage exists, the universal joint should be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Propeller Shaft > Page 4026 Drive/Propeller Shaft: Description and Operation Propeller Shaft Joint Angle DESCRIPTION When two shafts come together at a common joint, the bend that is formed is called the operating angle. The larger the angle, the larger the amount of angular acceleration and deceleration of the joint. This speeding up and slowing down of the joint must be cancelled to produce a smooth power flow. OPERATION This cancellation is done through the phasing of a propeller shaft and ensuring that the proper propeller shaft joint working angles are maintained. A propeller shaft is properly phased when the yoke ends are in the same plane, or in line. A twisted shaft will make the yokes out of phase and cause a noticeable vibration. When taking propeller shaft joint angle measurements, or checking the phasing, of two piece shafts, consider each shaft separately. Ideally the driveline system should have; Angles that are equal or opposite within 1 degree of each other. - Have a 3 degree maximum operating angle. - Have at least a 1/2 degree continuous operating (propeller shaft) angle. Fig. 7 Propeller shaft speed (rpm) is the main factor in determining the maximum allowable operating angle. As a guide to the maximum normal operating angles refer to (Fig. 7). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration Drive/Propeller Shaft: Testing and Inspection Vibration Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration. Refer to Steering and Suspension for additional information. Brake drums that are unbalanced will cause a harsh, low frequency vibration. Refer to Brakes and Traction Control, for additional information. Driveline vibration can also result from loose or damaged engine mounts. Refer to Engines, for additional information. Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a propeller shaft being unbalanced. Defective universal joints, or an incorrect propeller shaft angle, are usually the cause of such a vibration. Driveline Vibration Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4029 Drive/Propeller Shaft: Testing and Inspection Unbalance NOTE: Removing and re-indexing the propeller shaft, 450 at a time, relative to the companion flange may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: (1) Raise the vehicle. (2) Clean all the foreign material from the propeller shaft and the universal joints. (3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. (4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with the shaft. (5) Check the companion flange bolts torque. (6) Remove the wheels and tires. Install the wheel lug nuts to retain the brake drums or rotors. (7) Mark and number the shaft six inches from the yoke end at four positions 90° apart. (8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. Fig. 8 (9) Install a screw clamp at position 1 (Fig. 8). (10) Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test. (11) If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft. Fig. 9 (12) If the vibration decreased, install a second clamp (Fig. 9) and repeat the test. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4030 Fig. 10 (13) If the additional clamp causes an additional vibration, separate the clamps (1/4 inch above and below the mark). Repeat the vibration test (Fig. 10). (14) Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. (15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4031 Drive/Propeller Shaft: Testing and Inspection Runout (1) Remove dirt, rust, paint, and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. (2) The dial indicator must be installed perpendicular to the shaft surface. (3) Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that, the effects of the weld process will not enter into the measurements. (4) Refer to Runout Specifications chart. (5) If the propeller shaft runout is out of specification, remove the propeller shaft, index the shaft 45° , and re-install the propeller shaft. Measure shaft runout again. (6) If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation. (7) If the propeller shaft runout is not within specifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout. (8) Replace the propeller shaft if the runout still exceeds the limits. Runout Specifications Chart Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Page 4032 Drive/Propeller Shaft: Adjustments REAR AXLE PINION INPUT ANGLE Fig. 37 Adjust the rear axle pinion input angle on vehicles equipped with leaf springs with tapered shims (Fig. 37). Install tapered shims between the springs and axle pad to correct the angle. Refer to Steering and Suspension, for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Service Procedures Drive/Propeller Shaft: Service and Repair Service Procedures Driveline Angle Measurement Preparation Before measuring universal joint angles, the following must be done; Inflate all tires to correct pressure. - Check the angles in the same loaded or unloaded condition as when the vibration occurred. Propeller shaft angles change according to the amount of load in the vehicle. - Check the condition of all suspension components and verify all fasteners are torqued to specifications. - Check the condition of the engine and transmission mounts and verify all fasteners are torqued to specifications. Propeller Shaft Angle Measurement NOTE: The following procedure is depicted using an axle equipped with a pinion yoke. The procedure and principles are the same for axles equipped with a companion flange. ONE-PIECE PROPELLER SHAFT Fig. 14 To accurately check driveline alignment, raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn. Remove any external bearing snap rings (if equipped) from universal joint so that the inclinometer base sits flat. (1) Rotate the shaft until transmission/transfer case output yoke bearing cap is facing downward. Always make measurements from front to rear. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Service Procedures > Page 4035 Fig. 11 (2) Place Inclinometer on yoke bearing cap (A) parallel to the shaft (Fig. 11). Center bubble in sight glass and record measurement. This measurement will give you the transmission or Output Yoke Angle (A). Fig. 12 (3) Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing cap parallel to the shaft (Fig. 12). Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the propeller shaft angle (C). (4) Subtract smaller figure from larger (C minus A) to obtain transmission output operating angle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Service Procedures > Page 4036 Fig. 13 (5) Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing cap parallel to the shaft (Fig. 13). Center bubble in sight glass and record measurement. This measurement will give you the pinion shaft or input yoke angle (B). (6) Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules given below and the example in for additional information. Good cancellation of U-joint operating angles (within 1 inch). - Operating angles less than 3°. - At least 1/2 of one degree continuous operating (propeller shaft) angle. TWO-PIECE PROPELLER SHAFT Fig. 15 The procedure to measure the propeller shaft angles involved with a two-piece propeller shaft is the same as those for a one-piece propeller shaft. The following additional conditions also apply: The front half-shaft must be parallel to the rear axle pinion shaft. - The front and rear half-shafts must be offset by a minimum of 1/2 of a degree. From the transmission/transfer case output shaft and from each other. - Excessive variation in measurement angles of A, B or C indicate propeller mis-alignment. - Vertical alignment of a two-piece shaft at the yokes should be greater than one-half degree and as close to one degree as possible. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Service Procedures > Page 4037 Drive/Propeller Shaft: Service and Repair Removal and Installation REMOVAL (1) Raise and support vehicle on safety stands. (2) Shift the transmission to the Neutral position. (3) Using a suitable marker, mark a line across the axle companion flange and yoke for installation reference. (4) Using a suitable marker, mark the outline of the center bearing on the support bracket for installation reference, if equipped. (5) Using a suitable marker, mark the outline of the heat shield on the center bearing for installation reference, if equipped. (6) Remove bolts that attach the center bearing and heat shield to the support bracket, if equipped. (7) Remove the bolts holding the companion yoke to the companion flange. Fig. 17 (8) Slide the slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft (Fig. 17). INSTALLATION (1) Slide the slip yoke onto the transmission, or transfer case, output shaft. (2) Align and install the center bearing and heat shield to the support bracket, if necessary. (3) Install the bolts and tighten to 68 Nm (50 ft. lbs.) torque. (4) Align the installation reference marks made on the companion flange and yoke. (5) Position the companion yoke onto the companion flange. (6) Install the bolts to hold the companion yoke to the companion flange. Tighten the bolts to 108 Nm (80 ft. lbs.) torque. (7) Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Service Procedures > Page 4038 Drive/Propeller Shaft: Service and Repair Cleaning and Inspection (1) Clean all universal joint bores with cleaning solvent and a wire brush. (2) Inspect the yokes for distortion, cracks, and worn bearing cap bores. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint Universal Joint: Service and Repair Single Cardan Universal Joint NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the companion yoke after removing the cardan joint from the tube yoke. DISASSEMBLY Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. Fig. 18 (3) Remove snap rings from both sides of yoke (Fig. 18). (4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. (5) Position the yoke with the grease fitting, if equipped, pointing up. Fig. 19 (6) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 19). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4043 (7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. Fig. 20 (8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 20). CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY (1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. Fig. 21 (2) Position the cross in the yoke with its lube fitting, if equipped, pointing up (Fig. 21). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4044 Fig. 22 (3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 22). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. (4) Press the bearing cap into the yoke bore enough to install a snap ring. (5) Install a snap ring. (6) Repeat Step 3 and Step 4 to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. (7) Add grease to lube fitting, if equipped. (8) Install the propeller shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4045 Universal Joint: Service and Repair Double Cardan Joint DISASSEMBLY Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. Fig. 23 (3) Remove all the bearing cap snap rings (Fig. 23). (4) Set the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the link yoke. Fig. 24 (5) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws (Fig. 24). Be sure to remove grease fittings that interfere with removal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4046 Fig. 25 (6) Grasp the protruding bearing by vise jaws. Tap the link yoke with a mallet and drift to dislodge the bearing cap from the yoke (Fig. 25). Fig. 26 (7) Flip assembly and repeat Step 4, Step 5, and Step 6 to remove the opposite bearing cap. This will then allow removal of the cross centering kit assembly and spring (Fig. 26). (8) Press the remaining bearing caps out the other end of the link yoke as described above to complete the disassembly. ASSEMBLY During assembly, ensure that the alignment marks on the link yoke and propeller shaft yoke are aligned. (1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4047 Fig. 27 (2) Fit a cross into the propeller shaft yoke (Fig. 27). Fig. 28 (3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 28). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4048 Fig. 29 (4) Press the bearing cap into the yoke bore enough to install a snap ring (Fig. 29). (5) Install a snap ring. Fig. 30 (6) Flip the propeller shaft yoke and install the bearing cap onto the opposite trunnion. Install a snap ring (Fig. 30). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4049 Fig. 31 (7) Fit the link yoke on the remaining two trunnions and press both bearing caps into place (Fig. 31). (8) Install snap rings. Fig. 32 (9) Install the centering kit assembly inside the link yoke making sure the spring is properly positioned (Fig. 32). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4050 Fig. 33 (10) Place two bearing caps on opposite trunnions of the remaining cross. Fit the open trunnions into the link yoke bores and the bearing caps into the centering kit (Fig. 33). Fig. 34 (11) Press the remaining two bearing caps into place and install snap rings (Fig. 34). Fig. 35 (12) Tap the snap rings to allow them to seat into the grooves (Fig. 35). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan Universal Joint > Page 4051 Fig. 36 (13) Check for proper assembly. Flex the joint beyond center, it should snap over-center in both directions when correctly assembled (Fig. 36). (14) Install the propeller shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Torque Specifications Torque Specifications Engine Component Torque 4.7 L Flexplate bolts 60 Nm (45 ft. lbs.) Follow the tightening sequence in the image provided. 5.2 L " 75 Nm (55 ft. lbs.) 5.9 L " 75 Nm (55 ft. lbs.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 4060 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 4067 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 4068 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4072 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4073 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4074 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4083 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4087 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4091 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range Shifter Transfer Case: Customer Interest Transfer Case - Loss of Gear Range NUMBER: 21-21-99 GROUP: Transfer Case DATE: Nov. 19, 1999 SUBJECT: Loss Of Gear Range Selection Due To A Loose Transfer Case Shifter Lever Grommet OVERVIEW: This bulletin involves the replacement of a grommet on the transfer case lower shifter lever. MODELS: 2000 (AN) Dakota 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH FOUR WHEEL DRIVE (NV-231 AND NV-242) AND BUILT PRIOR TO SEPTEMBER 16, 1999 (MDH 0916XX). SYMPTOM/CONDITION: The vehicle operator may experience a condition where the transfer case can not be shifted into high or low range. This condition may have resulted from an incorrect shift procedure, where a low range transfer case shift is attempted when the vehicle is not in motion (a static shift). The incorrect shift, into or out of low range, may force the transfer case lower shifter lever grommet to come loose from the transfer case shifter. DIAGNOSIS: Inspect the transfer case shifter linkage. If the trunnion has come loose from the grommet in the transfer case lower shifter lever, then perform the Repair Procedure. PARTS REQUIRED: 1 05017960AA Grommet, Transfer Case Lower Shifter Lever REPAIR PROCEDURE: 1. Raise and support the vehicle. 2. Note how the original transfer case lower shifter lever grommet is positioned. 3. Remove the original lower shifter lever grommet from the shift linkage trunnion. 4. Install the new grommet (p/n 05017960AA) into its hole in the transfer case lower shifter lever. The technician may find installing the grommet easier if the flat end (not the tapered end) of the grommet is installed first. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range > Page 4101 5. Loosen the shift rod lock bolt at the trunnion. Be sure the rod does not bind in the trunnion (Figure 1). 6. Verify that the transfer case shift lever is in the 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range > Page 4102 7. Align the adjustment location hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly (Figure 2). 8. Insert an appropriately sized pin through the adjustment channel and through the locating hole to hold the shifter in the correct position. 9. Tighten the shift rod lock bolt to 10 Nm (90 in. lbs.) torque. 10. Remove the locating pin from the adjustment channel and locating hole. 11. Check the shift linkage for proper operation in all ranges. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-03-10-94 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range Shifter Transfer Case: All Technical Service Bulletins Transfer Case - Loss of Gear Range NUMBER: 21-21-99 GROUP: Transfer Case DATE: Nov. 19, 1999 SUBJECT: Loss Of Gear Range Selection Due To A Loose Transfer Case Shifter Lever Grommet OVERVIEW: This bulletin involves the replacement of a grommet on the transfer case lower shifter lever. MODELS: 2000 (AN) Dakota 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH FOUR WHEEL DRIVE (NV-231 AND NV-242) AND BUILT PRIOR TO SEPTEMBER 16, 1999 (MDH 0916XX). SYMPTOM/CONDITION: The vehicle operator may experience a condition where the transfer case can not be shifted into high or low range. This condition may have resulted from an incorrect shift procedure, where a low range transfer case shift is attempted when the vehicle is not in motion (a static shift). The incorrect shift, into or out of low range, may force the transfer case lower shifter lever grommet to come loose from the transfer case shifter. DIAGNOSIS: Inspect the transfer case shifter linkage. If the trunnion has come loose from the grommet in the transfer case lower shifter lever, then perform the Repair Procedure. PARTS REQUIRED: 1 05017960AA Grommet, Transfer Case Lower Shifter Lever REPAIR PROCEDURE: 1. Raise and support the vehicle. 2. Note how the original transfer case lower shifter lever grommet is positioned. 3. Remove the original lower shifter lever grommet from the shift linkage trunnion. 4. Install the new grommet (p/n 05017960AA) into its hole in the transfer case lower shifter lever. The technician may find installing the grommet easier if the flat end (not the tapered end) of the grommet is installed first. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range > Page 4108 5. Loosen the shift rod lock bolt at the trunnion. Be sure the rod does not bind in the trunnion (Figure 1). 6. Verify that the transfer case shift lever is in the 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 21-21-99 > Nov > 99 > Transfer Case - Loss of Gear Range > Page 4109 7. Align the adjustment location hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly (Figure 2). 8. Insert an appropriately sized pin through the adjustment channel and through the locating hole to hold the shifter in the correct position. 9. Tighten the shift rod lock bolt to 10 Nm (90 in. lbs.) torque. 10. Remove the locating pin from the adjustment channel and locating hole. 11. Check the shift linkage for proper operation in all ranges. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-03-10-94 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: Customer Interest MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 4124 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch Solenoid: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 4130 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4131 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Page 4137 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly Technical Service Bulletin # 21-13-99 Date: 990903 A/T - 45RFE Does Not Shift Smoothly NUMBER: 21-13-99 GROUP: Transmission DATE: Sep. 3, 1999 SUBJECT: 45RFE Drive Learn Procedure OVERVIEW: This bulletin involves a drive procedure of the 45RFE transmission that the technician may use to have the Transmission Control Module (TCM) learn the optimal shift parameters. MODELS: 2000 (AN) Dakota 2000 (DN) Durango 1999-2000 (WJ) Grand Cherokee SYMPTOM/CONDITION: The transmission may not shift smoothly. This condition may occur even after a Quick Learn procedure has been completed. DIAGNOSIS: The 45RFE transmission adapts to its mechanical tolerances by learning the clutch volume indexes (CVI's) as well as the duty cycle and other parameters that control shift quality. Performing a Quick Learn will simply reset all transmission adaptive values to factory preset values and it will exercise the transmission clutches to learn an approximate value for the clutch CVI's. Quick Learn should not be used as a remedy for shift quality complaints. Quick Learn resets more than 70 learn parameters to their preset values and will require them to be relearned. Quick Learn should only be used when a transmission has be replaced or overhauled, or when the Transmission Control Module has been replaced or flashed. Once Quick Learn is performed, an initial drive evaluation should be performed to determine if the transmission is shifting smoothly. NOTE: VERIFY THAT ALL APPLICABLE TECHNICAL SERVICE BULLETINS FOR SHIFT QUALITY HAVE BEEN PERFORMED PRIOR TO PERFORMING THE DRIVE LEARN PROCEDURE. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7000/7001 J1962 Cable The first step is to verify that the shifter linkage is adjusted properly and that the CHECK PRNDL fault (code 28) is not present. NOTE: A MISADJUSTED SHIFTER WILL NOT SET CODE 28. A MISADJUSTED SHIFTER CABLE WILL HOWEVER CAUSE POOR 2-3 SHIFT QUALITY. It is critical that the PRNDL code be OD when the shifter is in the OD position gate. Use the DRB III(R) to confirm that the correct code is present. If the shifter has a temporary code (T3 or T4) in the OD shifter position, then this is the most likely cause for consistent poor 2-3 shift quality. If the linkage is out of adjustment, then adjust the shifter linkage. Perform the portion of the 45RFE Drive Learn Procedure that will learn the specific shift characteristic for the shift problem in question. POLICY: Information Only Procedures Procedure To Learn A Smooth 1st Neutral To Drive Shift: Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-1 UD CVI. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 4144 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2). With the vehicle at a stop and the service brake applied, record the UD CVI while performing a Neutral to Drive shift. During the shift, the UD CVI will temporarily show a different value which is the 1st N-1 UD CVI. The 1st N-1 UD CVI account for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3). Repeat steps 1 and 2 until the recorded 1st N-1 UD CVI value stabilizes. NOTE: IT IS IMPORTANT THAT THIS PROCEDURE BE PERFORMED WHEN THE TRANSMISSION TEMPERATURE IS BETWEEN 80 - 110°F (27 - 43°C). IF THIS PROCEDURE TAKES TOO LONG TO COMPLETE FULLY FOR THE ALLOWED TRANSMISSION OIL TEMPERATURE, THE VEHICLE MAY BE RETURNED TO THE CUSTOMER WITH AN EXPLANATION THAT THE SHIFT WILL IMPROVE DAILY DURING NORMAL VEHICLE USAGE. THE TCM ALSO LEARNS AT HIGHER OIL TEMPERATURES, BUT THESE VALUES (LINE PRESSURE CORRECTION VALUES) ARE NOT AVAILABLE FOR VIEWING ON THE DRB III(R). Procedure To Learn A Smooth Neutral To Drive Garage Shift: Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the N-1 UD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE BETWEEN 80 - 110°F (27 - 43°C). 1). Start the vehicle engine and shift to drive. 2). Move the vehicle forward to a speed of at least 10 MPH and come to a stop. 3). Perform repeated N-1 shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-1 shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the UD CVI value stabilizes and the N-1 shifts become smooth. Procedure To Learn The 1st 2-3 Shift After A Restart Or Shift To Reverse: Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 80°F (27°C). 1). With the vehicle engine running, select reverse gear for over 2 seconds. 2). Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the OD CVI. During the shift, a different value will appear on the screen, which is the 1st 2-3 OD CVI. 3). Repeat steps 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Procedure To Learn A Smooth 2-3 And 3-4 Upshift: Use the following steps to have the TCM learn the OD and 4C CVI's. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2). Repeat step 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. Procedure To Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown: Use the following steps to have the TCM learn the UD shift volume. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control Module <--> [Control Module, A/T] > Component Information > Technical Service Bulletins > A/T - 45RFE Does Not Shift Smoothly > Page 4145 NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). At a vehicle speed between 40 - 60 MPH, perform repeated 4-3 kickdown shifts. 2). Repeat step 1 until the UD volume becomes somewhat stable and the shift becomes smooth. Procedure To Learn A Smooth 1-2 Upshift and 3-2 Kickdown: Use the following steps to have the TCM learn the 2C shift volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With a vehicle speed below 30 MPH and the transmission in 3rd gear, perform multiple 3-2 kickdowns. 2). Repeat step 1 until the 3-2 kickdowns become smooth and the 2C CVI becomes stable. Procedure To Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift: Use the following steps to have the TCM learn the LR volume. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle speed around 25-30 MPH in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2). Repeat step 1 until the LR CVI become stable and the manual 2-1 becomes smooth. Procedure To Learn A Smooth Neutral To Reverse Shift: Perform the following shifts. NOTE: THE TRANSMISSION OIL TEMPERATURE MUST BE ABOVE 110°F (43°C). 1). With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Transmission Control Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4149 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4150 Transmission Control System Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4151 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4160 Park/neutral Position Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4164 Transmission Speed Sensor: Description and Operation The speed sensor is located in the overdrive housing. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. One revolution of the output shaft produces 23 pulses. Input signals from the sensor are sent to the PCM for processing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4168 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the powertrain control module by the transmission temperature sensor. It is a thermistor located in the governor pressure sensor connector. The temperature readings are used to control engagement of the overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The powertrain control module (PCM) prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 30°F. If fluid temperature exceeds 260°F, the powertrain control module will cause a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel, also illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 230°F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Application and ID ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Anti-lock Brake .................................................................................................................................... ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > RWAL Brake System ABS Light: Description and Operation RWAL Brake System Refer to Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > RWAL Brake System > Page 4176 ABS Light: Description and Operation 4 Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, 4 Wheel Antilock Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Pump Motor Connector 2 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Controller Antilock Brake (CAB) EBC 325 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 4185 Controller Antilock Brake (CAB) EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4186 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Black 14 Way C1 Black 14 Way Controller Antilock Brake C2 Black 4 Way C2 Black 4 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4187 Controller Antilock Brake: Description and Operation The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a Vehicle Speed Signal (VSS) to the powertrain control module. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. 3. Disconnect the pump motor connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4190 4. Remove screws attaching CAB to the HCU). 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4-4.7 Nm (36-42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4191 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch lbs.). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System Hydraulic Control Assembly - Antilock Brakes: Specifications RWAL Valve Mounting Bolt 15-20 ft.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System > Page 4196 Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket bolts 10-12 ft.lb Mounting Nuts 102 in.lb CAB Screws 36-42 in.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Service and Repair Four Wheel Antilock Brake System NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Disconnect battery negative cable. HCU Brake Lines 2. Remove the brake lines from HCU. 3. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4199 4. Remove the nuts which attaches the assembly to the mounting bracket. 5. Remove the assembly from the vehicle. INSTALLATION 1. Install the antilock assembly into the bracket and tighten bolts to 14-15 Nm (10-12 ft. lbs.). 2. Connect the CAB harnesses. 3. Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). 4. Connect battery. 5. Bleed brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4200 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Wheel Antilock Brake System REMOVAL 1. Remove RWAL valve harness connector from the RWAL controller. 2. Remove the brake lines from the valve. RWAL Valve 3. Remove the valve mounting bolt and remove the valve from the bracket. INSTALLATION 1. Position the valve on the bracket and install the mounting bolt. Tighten the mounting bolt to 20-27 Nm (15-20 ft. lbs.). 2. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 3. Install the RWAL valve harness connector into the RWAL controller. 4. Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 4205 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Wheel Speed Sensors/Tone Wheels Front Wheel Speed Sensors/Tone Wheels Front FRONT Wheel Speed Sensors/Tone Wheels Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4208 Wheel Speed Sensors/Tone Wheels Rear REAR Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4209 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Left Front Right Front Wheel Speed Sensor Connector Right Front Rear Wheel Speed Sensor Connector Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4210 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor LT Gray 2 Way Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor (Sensor Side) 2 Way Left Front Wheel Speed Sensor (Sensor Side) Rear Wheel Speed Sensor 2 Way Rear Wheel Speed Sensor Right Front Wheel Speed Sensor LT Gray 2 Way Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 4211 Right Front Wheel Speed Sensor (Sensor Side) 2 Way Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, 4 Wheel Antilock Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4214 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System Wheel Speed Sensor: Service and Repair Rear Wheel Antilock Brake System REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Fig.9 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4217 Wheel Speed Sensor: Service and Repair Four Wheel Antilock Brake System Front Wheel Speed Sensor CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Wheel Speed Sensor REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4218 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4219 Wheel Speed Sensor: Service and Repair Tone Wheel Rear Wheel Antilock Brake System The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Front The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Refer to Transmission and Drivetrain, Drive axles, Bearings and Joints, Wheel Hub for the service procedure. Rear The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding OVERVIEW A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. BLEEDING PROCEDURE 1. Mount master cylinder in vise. Master Cylinder Bleeding - Typical 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir. 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4224 Brake Bleeding: Service and Repair Base Brake System BASE BRAKE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4225 Brake Bleeding: Service and Repair Antilock Brake System Four Wheel ABS Brake System ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. Refer to Brakes, Brake Bleeding, Service and Repairs, Service Procedures for procedure. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Rear Wheel Antilock Brake Bleeding OVERVIEW Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4226 PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use the adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair REMOVAL 1. Remove stop lamp switch. 2. Remove clip securing booster push rod to brake pedal. 3. Remove pedal pivot pin C-clip and slide pin out of support bracket and pedal. 4. Remove pedal and bushings. INSTALLATION 1. Replace bushings if worn or damaged. 2. Lubricate pedal bushings and pivot pin with Mopar multi mileage grease, Lubriplate, or a silicone grease. 3. Install bushings in pedal and position pedal in support. 4. Insert pivot pin through support and pedal bushings and install C-clip. 5. Install booster push rod on brake pedal and install push rod retainer clip. 6. Install stop lamp switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4233 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Brake Warning ..................................................................................................................................... ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service Precautions > Page 4234 Brake Warning Indicator: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Brake Warning Lamp The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the ON position and the park brake released, or comes on while driving, refer to Rear Wheel Antilock for vehicles equipped with a rear wheel anti-lock brake system, or refer to Antilock Brakes. If no brake system problem is found, the following procedure will help locate a faulty park brake switch or park brake switch sense circuit. 1. Check the fused ignition switch output (run/ start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the park brake switch wire harness connector still disconnected, check for continuity between the park brake switch sense circuit cavity of the park brake switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted park brake switch sense circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector A and the park brake switch wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Preliminary Diagnosis for further testing of the brake warning lamp and the instrument cluster circuitry. If not OK, repair the open park brake switch sense circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Bore 2.75 in Mounting Pins 22 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. 6. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. 7. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 8. Remove caliper and brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4241 4. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 6. Bleed base brake system. 7. Install wheel and tire assemblies. 8. Remove supports and lower vehicle. 9. Pump brake pedal to seat brake shoes. 10. Fill brake fluid reservoir. 11. Verify firm pedal before moving vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4242 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. Piston Dust Boot 2. Remove piston dust boot. Use screwdriver to push boot out of groove. Caliper Piston Removal 3. Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4243 Caliper Piston Seal 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. ASSEMBLY 1. Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper. 2. Coat caliper piston bore, piston and new piston seal with clean brake fluid. Fig 19 Installing Caliper Piston Seal 3. Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. 4. Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. Sliding Boot Onto Piston Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4244 5. Slide new seal boot over piston until boot lip seats in piston groove. Snapping Boot Folds Into Place 6. Push retainer part of boot forward until folds in boot snap into place. Installing Caliper Piston And Boot 7. Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. 8. Press caliper piston to bottom of bore. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4245 Seating Piston Dust Boot 9. Seat piston dust boot with Installer 8248 and Handle C-4171. Caliper Bleed Screw & Cap Installation 10. Install caliper bleed screw and bleed screw cap if removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4246 Brake Caliper: Service and Repair Cleaning and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Riveted brake pads should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4250 Brake Pad: Service and Repair REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. 6. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 7. Remove caliper slide pins. 8. Remove caliper and brake shoes . 9. Remove outboard brake shoe. Pry one end of shoe retainer spring away from caliper. Then tilt shoe upward and rotate it out of caliper. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4251 10. Remove inboard shoe by tilting shoe outward until retainer spring is clear of caliper piston. 11. Support caliper with wire from suspension component. Do not allow brake hose to support caliper weight. INSTALLATION 1. Clean slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with a thin coat of high temperature grease. 2. Install new slide pin bushings if necessary. 3. Install inboard shoe. Be sure retainer spring is firmly seated in caliper piston. 4. Insert outboard brake shoe in caliper. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4252 5. Insure the outboard shoe retainer spring are seated in the caliper. 6. Install caliper and brake shoes over rotor and into adapter. 7. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4253 8. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 9. Install wheel and tire assembly. 10. Remove support and lower vehicle. 11. Pump brake pedal to seat brake shoes. 12. Fill brake fluid reservoir. 13. Verify a firm brake pedal before moving vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Rotor Specifications Rotor Specifications DISC BRAKE ROTOR TYPE Ventilated ROTOR DIAMETER 287 mm (11.3 in.) STANDARD ROTOR THICKNESS 24 mm (0.945 in.) MINIMUM ROTOR THICKNESS 22.6 mm (0.889 in.) ROTOR THICKNESS VARIATION (MAX) 0.013 mm (0.0005 in.) ROTOR RUNOUT (MAX) 0.102 mm (0.004 in.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4257 Brake Rotor/Disc: Testing and Inspection Refer to Brakes, Testing and Inspection, Procedures, Base Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation Brake Rotor/Disc: Service and Repair Brake Rotor - Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper. 4. Remove retainers on wheel studs and remove rotor. INSTALLATION 1. Install rotor hub and install retainers. 2. Install brake caliper. 3. Install wheel and tire assembly. 4. Remove support and lower vehicle. 5. Depress brake pedal several times to seat brake shoes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor - Removal and Installation > Page 4260 Brake Rotor/Disc: Service and Repair Brake Rotor Machining The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the lathe. Equipment capable of machining only one side at a time may produce a tapered rotor. NOTE: A hub mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles hub/bearing. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Support Plate Mounting Bolts/Nuts 47 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4265 Backing Plate: Service and Repair REMOVAL 1. Remove wheel and tire assembly and brake drum. 2. Remove brake shoe assembly. 3. Remove parking brake cable from parking brake lever. 4. Compress parking brake cable retainer tabs. Then push retainer and cable through and out of support plate. 5. Disconnect brake line at wheel cylinder. 6. Remove wheel cylinder from support plate. 7. Remove axle shaft, refer to Transmission and Drivetrain for procedure. 8. Remove bolts attaching support plate to axle and remove support plate. INSTALLATION 1. Apply bead of silicone sealer around axle mounting surface of support plate. 2. Install support plate on axle flange. Tighten attaching bolts to 115 Nm (85 ft. lbs.). 3. Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel cylinder. 5. Install parking brake cable in support plate. 6. Install axle shaft. 7. Connect parking brake cable to lever on secondary shoe and install brake shoes on support plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake drum and wheel and tire assembly. 10. Bleed brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Specifications 9" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................... 9.00" Maximum Machine Limit ...................................................................................................................... ............................................................ 9.060" Discard Diameter ................................................................................................................................. .............................................................. 9.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 10" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 10.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 10.060" Discard Diameter ................................................................................................................................. ............................................................ 10.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 11" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 11.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 11.060" Discard Diameter ................................................................................................................................. ............................................................ 11.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4269 Brake Drum: Service and Repair The brake drums can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.12 - 0.20 mm (0.006 - 0.008 inch) at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.025 to 0.038 mm (0.001 to 0.0015 inch) are recommended and will generally provide the best surface finish. Be sure the drum is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks. The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge. CAUTION: Replace the drum if machining will cause the drum to exceed the maximum allowable diameter. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4273 Brake Shoe: Adjustments OVERVIEW The rear drum brakes are equipped with a self-adjusting mechanism. Under normal circumstances, the only time adjustment is required is when the shoes are replaced, removed for access to other parts, or when one or both drums are replaced. Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. ADJUSTMENT WITH BRAKE GAUGE 1. Be sure parking brakes are fully released. 2. Raise rear of vehicle and remove wheels and brake drums. 3. Verify that left and right automatic adjuster levers and cables are properly connected. 4. Insert brake gauge in drum. Expand gauge until gauge inner legs contact drum braking surface. Then lock gauge in position . Adjusting Brake Shoes With Gauge 5. Reverse gauge and install it on brake shoes. Position gauge legs at shoe centers as shown. If gauge does not fit (too loose/too tight), adjust shoes. 6. Pull shoe adjuster lever away from adjuster screw star wheel. 7. Turn adjuster screw star wheel (by hand) to expand or retract brake shoes. Continue adjustment until gauge outside legs are light drag-fit on shoes. 8. Install brake drums and wheels and lower vehicle. 9. Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8-10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. ADJUSTMENT WITH ADJUSTING TOOL 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4274 Fig. 6 Release type brake adjuster 5. Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel. 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver. 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. 12. Drive vehicle and make one forward stop followed by one reverse stop. Repeat procedure 8-10 times to operate automatic adjusters and equalize adjustment. NOTE: Bring vehicle to complete standstill at each stop. Incomplete, rolling stops will not activate automatic adjusters. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4275 Brake Shoe: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove drum. If drum is difficult to remove, remove rear plug from access hole in support plate. Back-off self adjusting by inserting a thin screwdriver into access hole and push lever away from adjuster screw star wheel. Then insert an adjuster tool into brake adjusting hole rotate adjuster star wheel to retract brake shoes. 5. Vacuum brake components to remove brake lining dust. 6. Remove shoe return springs with brake spring plier tool. 7. Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever. 8. Remove cable guide from secondary shoe and anchor plate from anchor pin. 9. Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. 10. Remove adjuster lever spring from pivot. 11. Disengage and remove shoe spring from brake shoes. 12. Disengage and remove adjuster screw assembly from brake shoes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4276 13. Remove brake shoe retainers, springs. 14. Remove secondary brake shoe from support plate. 15. Remove strut and spring. 16. Remove parking brake lever retaining clip from the secondary shoe and remove the lever. 17. Remove primary shoe from support plate. 18. Disengage parking brake lever from parking brake cable. INSTALLATION 1. Clean and inspect individual brake components, refer to the individual component for information. 2. Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. 3. Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. 4. Install the parking brake cable to the parking brake lever. 5. Install parking brake lever to the secondary shoe and install retaining clip. 6. Install primary shoe on support plate. Secure shoe with new spring retainers and pin. 7. Install spring on parking brake strut and engage strut in primary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4277 8. Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. 9. Install anchor plate and adjuster cable eyelet on support plate anchor pin. 10. Install cable guide in secondary shoe and position cable in guide. 11. Assemble adjuster screw. Then install and adjuster screw between the brake shoes. CAUTION: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. 12. Install adjuster lever and spring and connect adjuster cable to lever. 13. Install secondary shoe retainers and spring. 14. Install shoe spring. Connect spring to secondary shoe first, then to primary shoe. 15. Verify adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. 16. Adjust brake shoes to drum with brake gauge. 17. Install wheel and tire assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 1/4-20 11 ft.lb 5/16-18 16 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (16 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4283 Wheel Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4284 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding OVERVIEW A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. BLEEDING PROCEDURE 1. Mount master cylinder in vise. Master Cylinder Bleeding - Typical 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir. 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4290 Brake Bleeding: Service and Repair Base Brake System BASE BRAKE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Right Rear Wheel - Left Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4291 Brake Bleeding: Service and Repair Antilock Brake System Four Wheel ABS Brake System ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. Refer to Brakes, Brake Bleeding, Service and Repairs, Service Procedures for procedure. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Rear Wheel Antilock Brake Bleeding OVERVIEW Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. Bleed only one brake component at a time in the following sequence: Master Cylinder - Combination Valve - Rear Antilock Valve - Left Rear Wheel - Right Rear Wheel - Right Front Wheel - Left Front Wheel MANUAL BLEEDING 1. Remove reservoir filler caps and fill reservoir. 2. If calipers, or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 4292 PRESSURE BLEEDING Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Use the adapter provided with the equipment or Adapter 6921. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc Brake Caliper Type Sliding Bore 2.75 in Mounting Pins 22 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake shoe. 6. Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged. 7. With a screw driver pry up on the caliper spring and pull the spring out of the caliper holes. 8. Remove caliper and brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Install and tighten caliper slide pins to 30 Nm (22 ft. lbs.). Start the slide pins by hand before tightening. Do not cross thread the pins. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4298 4. Install caliper spring into one caliper hole and under the adapter. Pull down on the opposite end of the spring and hold the end under the adapter. With a screw driver pry up on the spring to seat the spring into the other caliper hole. NOTE: Verify the spring is seated properly into the caliper holes. 5. Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 Nm (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 6. Bleed base brake system. 7. Install wheel and tire assemblies. 8. Remove supports and lower vehicle. 9. Pump brake pedal to seat brake shoes. 10. Fill brake fluid reservoir. 11. Verify firm pedal before moving vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4299 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. Piston Dust Boot 2. Remove piston dust boot. Use screwdriver to push boot out of groove. Caliper Piston Removal 3. Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore. 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4300 Caliper Piston Seal 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. ASSEMBLY 1. Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper. 2. Coat caliper piston bore, piston and new piston seal with clean brake fluid. Fig 19 Installing Caliper Piston Seal 3. Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. 4. Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. Sliding Boot Onto Piston Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4301 5. Slide new seal boot over piston until boot lip seats in piston groove. Snapping Boot Folds Into Place 6. Push retainer part of boot forward until folds in boot snap into place. Installing Caliper Piston And Boot 7. Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. 8. Press caliper piston to bottom of bore. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4302 Seating Piston Dust Boot 9. Seat piston dust boot with Installer 8248 and Handle C-4171. Caliper Bleed Screw & Cap Installation 10. Install caliper bleed screw and bleed screw cap if removed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4303 Brake Caliper: Service and Repair Cleaning and Inspection CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. Fig 14 Honing Piston Bore The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4307 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4308 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. - Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4309 Brake Fluid: Service and Repair Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Black 2 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line Fittings Master Cylinder 170 in.lb Combination Valve 170 in.lb Wheel Cylinder 145 in.lb Brake Hose Front Fitting 145 in.lb Front Bolt 250 in.lb Rear Fitting 170 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4316 Brake Hose/Line: Service and Repair OVERVIEW A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. Inverted Flare And ISO Flare Special bending tools are needed to avoid kinking or twisting of metal brake tubes. Special flaring tools are needed to make a double inverted flare or ISO flare. DOUBLE INVERTED FLARING 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4317 Cutting And Flaring Of Brake Fluid Tubing 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO FLARING To make an ISO flare use Snap-On Flaring Tool TFM-428 or equivalent. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar. Then tighten the tool bar on the tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4318 5. Install the correct size adaptor on the flaring tool yoke screw. 6. Lubricate the adaptor. 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation Refer to Brakes, Description and Operation, Base Brake Systems and Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 4322 Brake Proportioning/Combination Valve: Service and Repair REMOVAL 1. Disconnect wire from the pressure differential switch. 2. Disconnect rear brake lines from combination valve. 3. Remove the bolt from the combination valve and remove the valve. INSTALLATION 1. Install the combination valve to the bracket and tighten the mounting bolt to 20-27 Nm (15-20 ft. lbs.). If vehicle is equipped with ABS brakes tighten the bolt to 10-13 Nm (7-10 ft. lbs.). 2. Install the brake lines to the combination valve. 3. Tighten the brake line to 19 Nm (170 inch lbs.). 4. Connect the wire to the pressure differential switch. 5. Bleed brakes system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System Hydraulic Control Assembly - Antilock Brakes: Specifications RWAL Valve Mounting Bolt 15-20 ft.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Rear Wheel Antilock System > Page 4327 Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Assembly Bracket bolts 10-12 ft.lb Mounting Nuts 102 in.lb CAB Screws 36-42 in.lb Brake Line Fittings 170 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System Hydraulic Control Assembly - Antilock Brakes: Service and Repair Four Wheel Antilock Brake System NOTE: If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Disconnect battery negative cable. HCU Brake Lines 2. Remove the brake lines from HCU. 3. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4330 4. Remove the nuts which attaches the assembly to the mounting bracket. 5. Remove the assembly from the vehicle. INSTALLATION 1. Install the antilock assembly into the bracket and tighten bolts to 14-15 Nm (10-12 ft. lbs.). 2. Connect the CAB harnesses. 3. Connect the brake lines to the HCU. Tighten brake line fittings to 19 Nm (170 inch lbs.). 4. Connect battery. 5. Bleed brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 4331 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Rear Wheel Antilock Brake System REMOVAL 1. Remove RWAL valve harness connector from the RWAL controller. 2. Remove the brake lines from the valve. RWAL Valve 3. Remove the valve mounting bolt and remove the valve from the bracket. INSTALLATION 1. Position the valve on the bracket and install the mounting bolt. Tighten the mounting bolt to 20-27 Nm (15-20 ft. lbs.). 2. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 3. Install the RWAL valve harness connector into the RWAL controller. 4. Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 160 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4335 Brake Master Cylinder: Description and Operation Refer to Brakes, Description and Operation, Base Brake Systems and Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4336 Brake Master Cylinder: Testing and Inspection Refer to Brakes, Testing and Inspection, Procedures, Base Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Procedure OVERVIEW A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. BLEEDING PROCEDURE 1. Mount master cylinder in vise. Master Cylinder Bleeding - Typical 2. Attach bleed tubes to cylinder outlet ports. Then position each tube end into reservoir. 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4339 Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation REMOVAL Master Cylinder 1. Remove brake lines from the master cylinder. 2. Remove mounting nuts from the master cylinder. 3. Remove master cylinder. INSTALLATION NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install master cylinder on booster mounting studs. 2. Install mounting nuts and tighten to 18 Nm (160 inch lbs.) 3. Install brake lines and tighten to 19 Nm (170 inch lbs.) 4. Fill and bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4340 Brake Master Cylinder: Service and Repair Fluid Reservoir Removal and Installation REMOVAL 1. Remove reservoir cap and empty fluid into drain container. 2. Clamp cylinder body in vise with brass protective jaws. 3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins. 4. Loosen reservoir from grommets with pry tool. Brake Fluid Reservoir Removal Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Procedure > Page 4341 5. Remove reservoir by rocking it to one side and pulling free of grommets. Grommet Removal 6. Remove old grommets from cylinder body. INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. Brake Fluid Reservoir Grommet Installation 1. Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. 2. Start reservoir in grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets. 3. Install pins that retain reservoir to cylinder body. 4. Fill and bleed master cylinder on bench before installation in vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 1/4-20 11 ft.lb 5/16-18 16 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and tighten to 20 Nm (16 ft. lbs.). 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed base brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4347 Wheel Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4348 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable Parking Brake Cable: Service and Repair Front Parking Brake Cable REMOVAL 1. Raise and support the vehicle. 2. Loosen the cable adjuster nut. 3. Pull cable through the body mount. 4. Remove support and lower vehicle. 5. Remove left kick panel. 6. Fold left front edge of floor covering rearward and remove cable grommet from floor pan. 7. Engage parking brake pedal and remove cable from park brake pedal assembly. 8. Pull the cable through the floor pan. 9. Remove cable from vehicle. INSTALLATION 1. Insert front cable through floor pan and install grommet. 2. Insert cable retainer into hole at bottom of pedal assembly bracket and connect cable end. 3. Install kick panel. 4. Raise and support vehicle. 5. Insert the cable through the body mount. 6. Connect the cable to the tensioner. 7. Perform parking brake adjustment procedure. 8. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4354 Parking Brake Cable: Service and Repair Rear Parking Brake Cable REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Loosen tensioner adjuster nut. 4. Remove the right cable from the tensioner and pull the cable housing through the left cable connector. 5. Remove the left cable connector. 6. Pull both cables through the cable bracket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable > Page 4355 7. Remove the right cable mounting retainers from the stabilizer bar retainers and remove the cable from the differential housing. 8. Remove the brake drums. 9. Disconnect each cable from park brake lever. 10. Compress tabs on each cable housing retainer at the brake support plate. 11. Remove the cables from the brake support plates. INSTALLATION 1. Push each cable housing through the brake support plate hole until cable housing retainer tabs lock into place. NOTE: Pull on the cable housing to ensure it is lock into place. 2. Pull back on the end of the cable. Then push the cable in to engage the cable in the park brake lever. NOTE: Pull on the cable end to ensure it is attached it the park brake lever. 3. Install the brake drums. 4. Install right cable mounting retainers. 5. Push the cables housing through the cable bracket 6. Install the left cable onto the cable connector. 7. Push the right cable housing through the left cable connector and connect the cable to the tensioner. 8. Install the wheel and tire assemblies. 9. Perform park brake adjustment procedure. 10. Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair REMOVAL 1. Remove left side kick panel. 2. Remove brake release rod from pedal assembly. 3. Disconnect brake warning lamp switch. 4. Remove front parking brake cable. 5. Remove mounting nuts and mounting bolt. 6. Slide assembly rearward off the mounting studs. INSTALLATION 1. Install assembly on the mounting studs. 2. Install mounting bolt and nuts. 3. Install front parking brake cable. 4. Connect brake warning lamp switch. 5. Install brake release rod to pedal assembly. 6. Install left side kick panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise vehicle. 2. Back off cable tensioner adjusting nut create slack in cables. 3. Remove rear wheel/tire assemblies. Then remove brake drums. 4. Verify brakes are in good condition and operating properly. 5. Verify park brake cables operate freely and are not binding, or seized. 6. Check rear brake shoe adjustment with standard brake gauge. 7. Install drums and verify that drums rotate freely without drag. 8. Install wheel/tire assemblies. 9. Lower vehicle enough for access to park brake foot pedal. Then fully apply park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise vehicle again. 11. Mark tensioner rod 6.35 mm (1/4 inch) from edge of tensioner if no mark is visible. NOTE: The rod is marked from the factory. 12. Tighten adjusting nut on tensioner until the 1/4 inch mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower vehicle until rear wheels are 15 - 20 cm (6 - 8 inch) off shop floor. 14. Release park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake Booster Type Tandem Diaphragm Mounting Nuts 250 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4366 Vacuum Brake Booster: Description and Operation Refer to Brakes, Description and Operation, Base Brake Systems and Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4367 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum lines at booster. 3. Remove clip securing booster push rod to brake peda. 4. Remove nuts from booster mounting studs. 5. Remove booster, spacer and gaskets from front cowl panel. INSTALLATION 1. Position spacer and gaskets on booster studs. 2. Guide booster studs into cowl panel holes and seat booster on panel. 3. Install and tighten booster attaching nuts to 28 Nm (250 inch lbs.). 4. Install booster push rod on brake pedal and install clip. 5. Install booster check valve if removed and connect vacuum hose to check valve. 6. Install master cylinder. 7. Fill and bleed brake system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications Controller Antilock Brake: Specifications Controller Mounting Screws 53 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 Controller Antilock Brake (CAB) EBC 325 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 325 > Page 4374 Controller Antilock Brake (CAB) EBC 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4375 Controller Antilock Brake: Diagrams Controller Antilock Brake C1 Black 14 Way C1 Black 14 Way Controller Antilock Brake C2 Black 4 Way C2 Black 4 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4376 Controller Antilock Brake: Description and Operation The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a Vehicle Speed Signal (VSS) to the powertrain control module. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System Controller Antilock Brake: Service and Repair Four Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Disconnect battery negative cable. 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. 3. Disconnect the pump motor connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4379 4. Remove screws attaching CAB to the HCU). 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4-4.7 Nm (36-42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Antilock System > Page 4380 Controller Antilock Brake: Service and Repair Rear Wheel Antilock System NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type refer to Transmission and Drivetrain, Differential. For tire revolutions per mile refer to Steering and Suspension, Tires, Wheels and Alignment. To program the CAB refer to Testing and Inspection, Procedures, Diagnostic Information and Procedures. REMOVAL 1. Push the CAB harness connector lock to release the lock and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket. 2. Install the mounting screws and tighten to 6 Nm (53 inch lbs.). 3. Install the RWAL valve harness connector into the controller. 4. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Pressure Switch Black 2 Way Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 in.lb Rear Sensor Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Four Wheel Antilock Brake System > Page 4389 Wheel Speed Sensor: Specifications Wheel Speed Sensor Mounting Bolt 200 in.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Wheel Speed Sensors/Tone Wheels Front Wheel Speed Sensors/Tone Wheels Front FRONT Wheel Speed Sensors/Tone Wheels Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4392 Wheel Speed Sensors/Tone Wheels Rear REAR Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 4393 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Left Front Right Front Wheel Speed Sensor Connector Right Front Rear Wheel Speed Sensor Connector Rear Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4394 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor LT Gray 2 Way Left Front Wheel Speed Sensor Left Front Wheel Speed Sensor (Sensor Side) 2 Way Left Front Wheel Speed Sensor (Sensor Side) Rear Wheel Speed Sensor 2 Way Rear Wheel Speed Sensor Right Front Wheel Speed Sensor LT Gray 2 Way Right Front Wheel Speed Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4395 Right Front Wheel Speed Sensor (Sensor Side) 2 Way Right Front Wheel Speed Sensor (Sensor Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, 4 Wheel Antilock Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brake System > Page 4398 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System Wheel Speed Sensor: Service and Repair Rear Wheel Antilock Brake System REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Fig.9 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4401 Wheel Speed Sensor: Service and Repair Four Wheel Antilock Brake System Front Wheel Speed Sensor CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 21 Nm (190 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Wheel Speed Sensor REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4402 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 O-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 (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Antilock Brake System > Page 4403 Wheel Speed Sensor: Service and Repair Tone Wheel Rear Wheel Antilock Brake System The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Front The tone wheel for the front speed sensor is located on the hub/bearing on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. To replace the tone wheel the hub/bearing must be replaced. Refer to Transmission and Drivetrain, Drive axles, Bearings and Joints, Wheel Hub for the service procedure. Rear The exciter ring is mounted on the differential case. If the ring is damaged refer to Transmission and Drivetrain, Differential for service procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4409 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4410 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4411 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4412 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4417 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4418 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4419 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4420 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4421 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4422 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair REMOVAL (1) Raise vehicle and position drain pan under switch. (2) Disconnect switch wires. (3) Remove switch from case. INSTALLATION Fig. 79 (1) Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case (Fig. 79). (2) Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. (3) Test continuity of new switch with 12V test lamp. (4) Connect switch wires and lower vehicle. (5) Top off transmission fluid level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4430 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4431 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4432 Starter Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4433 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for starter relay identification and location. The starter relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil ill the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4434 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) 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 in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit to the park/neutral position switch is OK, refer to Park/Neutral Position Switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4435 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Testing and Inspection Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temperature Sensor Location The Battery Temperature Sensor is located under vehicle battery and is attached to a mounting hole on battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4443 Battery Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4444 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4445 Battery Temperature Sensor: Testing and Inspection Tests 1 - 2 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - BTS (out of calibration) - Wiring harness intermittent problem Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4446 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under vehicle battery and is attached to a mounting hole on battery tray. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray. 2. Connect pigtail harness. 3. Install battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL 1. Turn the ignition switch to the OFF position. Be certain that all electrical accessories are turned OFF. 2. Loosen the battery negative cable terminal clamp pinch-bolt hex nut. 3. Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post. 4. Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post. Battery Hold Downs Remove/Install 5. Remove the two hold down bolts that secure the hold down strap/battery thermoguard unit to the U-nuts in the battery tray. 6. Remove the hold down strap/battery thermoguard unit from the top of the battery case. INSTALLATION 1. Clean and inspect the battery hold down hardware. 2. Install the hold down strap/battery thermoguard unit over the top of the battery case. 3. Install and tighten the two hold down bolts that secure the hold down strap/battery thermoguard unit to the U-nuts in the battery tray. Tighten the bolts to 2.1 Nm (19 in. lbs.). 4. Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in. lbs.). 5. Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 Nm (70 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4451 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Remove the battery from the battery tray. 2. Remove the Power Distribution Center (PDC) from the stanchions on the rear of the battery tray. Battery Tray Remove/Install 3. Remove the two screws that secure the inboard side of the battery tray to the battery tray support. 4. Remove the two screws that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel. 5. Remove the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. 6. Remove the battery temperature sensor from the battery tray. 7. Remove the battery tray from the battery tray support and the front extension of the left front wheelhouse inner panel. 8. Remove the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. 9. Remove the two screws that secure the front of the battery tray support to the left side of the radiator yoke. 10. Remove the battery tray support from the left front wheelhouse inner panel and the left side of the radiator yoke. INSTALLATION 1. Clean and inspect the battery tray. 2. Position the battery tray support onto the left front wheelhouse inner panel and the left side of the radiator yoke. 3. Install and tighten the two screws that secure the battery tray support to the left side of the radiator yoke. Tighten the screws to 11.3 Nm (100 in. lbs.). 4. Install and tighten the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel. Tighten the screw to 11.3 Nm (100 in. lbs.). 5. Install the battery temperature sensor onto the battery tray. 6. Position the battery tray onto the battery tray support and the front extension of the left front wheelhouse inner panel. Be certain that the battery temperature sensor wiring is properly routed. 7. Install and tighten the two screws (rear screw first) that secure the outboard side of the battery tray to the front extension of the left front wheelhouse inner panel. Tighten the screws to 12.4 Nm (110 in. lbs.). 8. Install and tighten the two screws that secure the inboard side of the battery tray to the battery tray support. Tighten the screws to 12.4 Nm (110 in. lbs.). 9. Install and tighten the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. Tighten the screw to 12.4 Nm (110 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 4452 10. Install the Power Distribution Center (PDC) onto the stanchions on the rear of the battery tray. 11. Install the battery onto the battery tray. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Type Part Number Rated SAE Amps Minimum Test Amps Denso 56027912AB 117 A 90 A Denso 56027913AB 136 A 100 A Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4457 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4458 Generator Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Technician Safety Information Alternator: Technician Safety Information WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Technician Safety Information > Page 4461 Alternator: Vehicle Damage Warnings WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Page 4462 Alternator: Description and Operation The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Page 4463 Alternator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. Remove/Install Generator 3. Remove generator pivot and mounting bolts/nut. Position generator for access to wire connectors. Generator Connectors - Typical Bosch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service Precautions > Page 4464 Generator Connectors - Typical Denso 4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator. 5. Disconnect field wire connector at rear of generator by pushing on connector tab and pulling connector from generator. 6. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and snap field wire connector into rear of generator. 2. Install B+ terminal to generator mounting stud. Tighten mounting nut to 8.5 Nm (75 in. lbs.) torque. 3. Install generator mounting fasteners and tighten as follows: - Generator mounting bolt engines 41 Nm (30 ft. lbs.) torque. - Generator pivot bolt/nut 41 Nm (30 ft. lbs.) torque. CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. 4. Install generator drive belt. 5. Snap cable protector cover to B+ mounting stud (if equipped). 6. Install negative battery cable to battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations Voltage Regulator: Locations The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Locations > Page 4468 Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of direct current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100 Hz), but has the capability to ground the field control wire 100 % of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25 % is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations Ignition Switch Lock Cylinder: Locations The electrical ignition switch is located on the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4474 Ignition Switch Lock Cylinder: Description and Operation The electrical ignition switch is located on the steering column. It is used as the main ON/OFF switching device for most electrical components. The mechanical key lock cylinder is used to engage/disengage the electrical ignition switch. Vehicles equipped with an automatic transmission and a floor mounted shifter: a cable is used to connect the interlock device in the steering column assembly, to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is rotated to the LOCKED or ACCESSORY position. The interlock device within the steering column is not serviceable. If repair is necessary, the steering column assembly must be replaced. If the ignition key is difficult to rotate to or from the LOCK or ACCESSORY position, it may not be the fault of the key cylinder or the steering column components. The brake transmission shift interlock cable may be out of adjustment. Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmission shifter in the PARK position when the key lock cylinder is in the LOCKED or ACCESSORY position. If it is difficult to rotate the key to or from the LOCK or ACCESSORY position, the interlock device within the steering column may be defective. This device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and a LEVER below the ignition key: A lever is located on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Vehicles equipped with a manual transmission, a floor mounted shifter, and NO LEVER below the ignition key: The ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be defective. This mechanism is not serviceable. If repair is necessary, the steering column assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4475 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4476 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In Run Position Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4477 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Ignition Switch View From Column Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4478 Park Lock Linkage-Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. Steering Wheel Lock Lever 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 2 Nm ± 0.5 Nm (17 in. lbs. ± 5 in. lbs.) torque. e. After installing ignition switch, rotate ignition key from LOCK to ON position. Verify that park lock slider moves in slider slot, allowing gear- Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Locations > Page 4479 shift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is locked in PARK, the ignition switch park lock dowel pin, on rear of ignition switch, is not properly installed in slot of park lock slider linkage. Remove ignition switch and reinstall. 11. Connect electrical connectors to ignition switch, halo lamp and (if equipped ), to "PRNDL". Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel at least 180° to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair REMOVAL (1) Raise vehicle and position drain pan under switch. (2) Disconnect switch wires. (3) Remove switch from case. INSTALLATION Fig. 79 (1) Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case (Fig. 79). (2) Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. (3) Test continuity of new switch with 12V test lamp. (4) Connect switch wires and lower vehicle. (5) Top off transmission fluid level. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Manufacturer Denso Power Rating 1.4 kW Voltage 12 V Free Running Test Voltage 11 V Free Running Test Maximum Amperage Draw 73 A Solenoid Closing Maximum Voltage Required 7.5 V Cranking Amperage Draw Test 125 - 250 A Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4487 Starter Motor: Mechanical Specifications Manufacturer Denso Part Number 56027702AC Pinion Teeth 10 Number Of Fields 4 Number Of Poles 4 Number Of Brushes 4 Drive Type Reduction Gear Train Free Running Test Minimum Speed 3601 rpm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4488 Starter Motor: Description and Operation The starter motors used for these engines available in this model are interchangeable. The starter motors for all of the remaining engines are mounted with one screw, a stud and a nut to the automatic transmission torque converter housing and are also located on the left side of the engine. Each of these starter motors incorporates several of the same features to create a reliable, efficient, compact, lightweight and powerful unit. The electric motors of both starters have four brushes contacting the motor commutator. These starter motors use four electromagnetic field coils wound around four pole shoes. The starter motors are rated at 1.4 kilowatts (about 1.9 horsepower) output at 12 volts. These starter motors are serviced only as a unit with their starter solenoids, and cannot be repaired. If either component is faulty or damaged, the entire starter motor and starter solenoid unit must be replaced. These starter motors are equipped with a gear reduction (intermediate transmission) system. The gear reduction system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the starter pinion gear to the starter ring gear. The starter motors for all engines are activated by an integral heavy duty starter solenoid switch mounted to the overrunning clutch housing. This electromechanical switch connects and disconnects the feed of battery voltage to the starter motor and actuates a shift fork that engages and disengages the starter pinion gear with the starter ring gear. These starter motors use an overrunning clutch and starter pinion gear unit to engage and drive a starter ring gear that is integral to the torque converter or torque converter drive plate mounted on the rear crankshaft flange. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4489 Starter Motor: Testing and Inspection Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with the starter motor removed from the vehicle. 1. Remove the starter motor from the vehicle. 2. Mount the starter motor securely in a softjawed bench vise. The vise jaws should be clamped on the mounting flange of the starter motor. Never clamp on the starter motor by the field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to the starter motor in series, and set the ammeter to the 100 ampere scale. See the instructions provided by the manufacturer of the volt-ampere tester being used. 4. Install a jumper wire from the solenoid terminal to the solenoid battery terminal. The starter motor should operate. If the starter motor fails to operate, replace the faulty starter motor assembly. 5. Adjust the carbon pile load of the tester to obtain the free running test voltage. Refer to Starting System for the starter motor free running test voltage specifications. 6. Note the reading on the ammeter and compare this reading to the free running test maximum amperage draw. Refer to Starting System for the starter motor free running test maximum amperage draw specifications. 7. If the ammeter reading exceeds the maximum amperage draw specification, replace the faulty starter motor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4490 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. Starter Motor Remove/Install 3. Remove the nut and the lock washer that secures the lower mounting flange of the starter motor to the stud on the automatic transmission torque converter housing. 4. While supporting the starter motor with one hand, use the other hand to remove the screw and washer that secures the upper mounting flange of the starter motor to the automatic transmission torque converter housing. 5. Slide the automatic transmission cooler tube bracket forward on the tubes far enough for the starter motor mounting flange to be removed from the lower mounting stud. 6. Lower the starter motor from the front of the automatic transmission torque converter housing far enough to access and remove the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 7. Remove the battery positive cable eyelet terminal from the solenoid B(+) terminal stud. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 8. Disconnect the battery positive cable solenoid terminal wire harness connector from the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 9. Remove the starter motor from the automatic transmission torque converter housing. INSTALLATION 1. Position the starter motor to the automatic transmission torque converter housing. 2. Reconnect the battery positive cable solenoid terminal wire harness connector to the connector receptacle on the starter solenoid. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 3. Install the battery positive cable eyelet terminal onto the solenoid B(+) terminal stud. Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 4. Install and tighten the nut that secures the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Tighten the nut to 13.6 Nm (120 in. lbs.). Always support the starter motor during this process. Do not let the starter motor hang from the wire harness. 5. Position the hole in the starter motor lower mounting flange over the stud on the automatic transmission torque converter housing. 6. Slide the automatic transmission cooler tube bracket rearward on the tubes and into position over the starter motor upper mounting flange. 7. Loosely install the screw and washer unit that secures the starter motor upper mounting flange to the automatic transmission torque converter housing. 8. Loosely install the lock washer and nut that secures the starter motor lower mounting flange to the stud on the automatic transmission torque converter housing. 9. Tighten the screw and washer unit and the nut that secure the starter motor mounting flange to the automatic transmission torque converter housing. Tighten the screw and the nut to 67.8 Nm (50 ft. lbs.). 10. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4491 11. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Starter Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4495 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4496 Starter Relay: Diagrams Power Distribution Center Engine Starter Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4497 Starter Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4498 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay layout label affixed to the inside surface of the PDC cover for starter relay identification and location. The starter relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The starter relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil ill the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4499 Starter Relay: Testing and Inspection Starter Relay The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 1. Remove the starter relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) 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 in the PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the ON position. If OK, go to Step 5. If not OK, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. Check for continuity to ground at the cavity for relay terminal 85. If not OK, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit to the park/neutral position switch is OK, refer to Park/Neutral Position Switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4500 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. See the fuse and relay layout label affixed to the underside of the PDC cover for starter relay identification and location. 4. Remove the starter relay from the PDC. INSTALLATION 1. See the fuse and relay layout label affixed to the underside of the PDC cover for the proper starter relay location. 2. Position the starter relay in the proper receptacle in the PDC. 3. Align the starter relay terminals with the terminal cavities in the PDC receptacle. 4. Push down firmly on the starter relay until the terminals are fully seated in the terminal cavities in the PDC receptacle. 5. Install the cover onto the PDC. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection This test can only be performed with the starter motor removed from the vehicle. 1. Remove the starter motor from the vehicle. 2. Disconnect the wire from the solenoid field coil terminal. Continuity Test Between Solenoid Terminal And Field Coil Terminal - Typical 3. Check for continuity between the solenoid terminal and the solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace the faulty starter motor assembly. Continuity Test Between Solenoid Terminal And Solenoid Case - Typical 4. Check for continuity between the solenoid terminal and the solenoid case. There should be continuity. If not OK, replace the faulty starter motor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4529 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4530 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4531 Auxiliary Power Outlet: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4532 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center (PDC): Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 Power Distribution Center (PDC): Diagrams C106 C108 C106 (In PDC) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4538 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4539 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4540 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4541 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION SYSTEM This information covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Relay and Fuse Block. The power distribution system also incorporates various types of circuit control and protection features, including: Automatic resetting circuit breakers Blade-type fuses Cartridge fuses - Circuit splice blocks - Flashers - Relays. Following are general descriptions of the major components in the power distribution system. See the owner's manual in the vehicle glove box for more information on the features and use of all of the power distribution system components. The power distribution system for this vehicle is designed to provide safe, reliable, and centralized distribution points for the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience systems. At the same time, the power distribution system was designed to provide ready access to these electrical distribution points for the vehicle technician to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional electrical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket. POWER DISTRIBUTION CENTER Power Distribution Center Location All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to thirteen International Standards Organization (ISO) relays (one standard-type and twelve micro-type), two joint connectors (one sixteen-way and one twenty-six-way) and a sixteen-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4542 All of the current from the battery and the generator output enters the PDC through two cables with eyelets that are secured with nuts to the two B(+) terminal studs located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is used on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. JUNCTION BLOCK Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged; the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. IGNITION-OFF DRAW FUSE Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4543 Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. RELAY AND FUSE BLOCK Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4544 Relay And Fuse Block Location The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel. The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4545 Power Distribution Center (PDC): Service and Repair The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Unlatch and remove the cover from the PDC. Engine Wire Harness In-Line Connector 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4546 Battery and Generator Connections to PDC 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC and remove the eyelet from the stud. Power Distribution Center Remove/Install 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit off of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4547 INSTALLATION NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC, 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 13. Reconnect each of the headlamp and dash wire harness connectors. 14. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 4552 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4555 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4556 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4557 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4558 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4559 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4560 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4561 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4562 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4563 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4564 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4565 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4566 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4567 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4570 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Page 4571 Fuse: Description and Operation GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is used on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Page 4572 Fuse: Service and Repair Generator Cartridge Fuse If a generator cartridge fuse fails, be certain to inspect and test the vehicle charging system before replacing the cartridge fuse and returning the vehicle to service. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unlatch and remove the cover from the Power Distribution Center (PDC). 3. Remove the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. 4. Remove the generator cartridge fuse from the PDC. INSTALLATION 1. Position the generator cartridge fuse onto the two B(+) terminal stud bus bars within the PDC. 2. Install and tighten the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. Tighten the screws to 3.4 Nm (30 in. lbs.). Be certain that both screws are tightened to the proper torque value. 3. Install and latch the cover onto the PDC. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 4577 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 8w-12-4 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Fuse Block: Electrical Diagrams 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 8w-12-3 Fuse/Relay Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 8w-11-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 8w-11-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 8w-11-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 8w-11-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4633 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4636 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4637 Fuse Block: Description and Operation JUNCTION BLOCK Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged; the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. RELAY AND FUSE BLOCK Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4638 Relay And Fuse Block Location The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel. The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block Fuse Block: Service and Repair Fuse/Relay Block The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Relay and Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 4641 Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles. 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 4642 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4647 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4648 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4649 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4653 Ignition Off-Draw (IOD) Fuse: Service and Repair Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the Oft position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. REMOVAL 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4659 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4662 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4663 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4664 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4665 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4666 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4667 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4668 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4669 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4670 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4671 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4672 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4673 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4674 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4677 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4682 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4685 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4686 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4687 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4688 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4689 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4690 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4691 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4692 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4693 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4694 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4695 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4696 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4697 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4700 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4705 Ignition Off-Draw (IOD) Fuse: Service and Repair Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the Oft position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. REMOVAL 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4731 Auxiliary Power Outlet: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4732 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the PDC. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the PDC fuse as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4733 Auxiliary Power Outlet: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4734 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center (PDC): Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 Power Distribution Center (PDC): Diagrams C106 C108 C106 (In PDC) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4740 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4741 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > C106 > Page 4742 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4743 Power Distribution Center (PDC): Description and Operation POWER DISTRIBUTION SYSTEM This information covers the various standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: Power Distribution Center (PDC) - Junction Block (JB) - Relay and Fuse Block. The power distribution system also incorporates various types of circuit control and protection features, including: Automatic resetting circuit breakers Blade-type fuses Cartridge fuses - Circuit splice blocks - Flashers - Relays. Following are general descriptions of the major components in the power distribution system. See the owner's manual in the vehicle glove box for more information on the features and use of all of the power distribution system components. The power distribution system for this vehicle is designed to provide safe, reliable, and centralized distribution points for the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience systems. At the same time, the power distribution system was designed to provide ready access to these electrical distribution points for the vehicle technician to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional electrical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket. POWER DISTRIBUTION CENTER Power Distribution Center Location All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the battery. The PDC houses the generator cartridge fuse and up to ten maxi-type cartridge fuses, which replace all in-line fusible links. The PDC also houses up to seven blade-type mini fuses, up to thirteen International Standards Organization (ISO) relays (one standard-type and twelve micro-type), two joint connectors (one sixteen-way and one twenty-six-way) and a sixteen-way engine wire harness in-line connector. The PDC housing is secured in the engine compartment at three points. Integral mounts on the front and inboard sides of the PDC housing engage and latch to stanchions that are integral to the molded plastic battery tray. An integral bracket on the rear of the PDC housing is secured with a screw to the top of the left front inner wheel house. The PDC housing has a molded plastic cover that includes two integral latches, one on each side. The PDC cover is easily opened and removed for service access and has a convenient fuse and relay layout map integral to the inside surface of the cover to ensure proper component identification. The PDC unit cannot be repaired and is only serviced as a unit with the headlamp and dash wire harness. If the internal circuits or the PDC housing are faulty or damaged, the headlamp and dash wire harness unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4744 All of the current from the battery and the generator output enters the PDC through two cables with eyelets that are secured with nuts to the two B(+) terminal studs located just inside the inboard side of the PDC housing. The PDC cover is unlatched and removed to access the battery and generator output connection B(+) terminal studs, the fuses, the relays, the joint connectors and the engine wire harness inline connector. Internal connection of all of the PDC circuits is accomplished by an intricate combination of hard wiring and bus bars. GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is used on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. JUNCTION BLOCK Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged; the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. IGNITION-OFF DRAW FUSE Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4745 Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. RELAY AND FUSE BLOCK Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4746 Relay And Fuse Block Location The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel. The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4747 Power Distribution Center (PDC): Service and Repair The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect each of the headlamp and dash wire harness connectors. 3. Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 4. Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 5. Unlatch and remove the cover from the PDC. Engine Wire Harness In-Line Connector 6. Disconnect the engine wire harness in-line connector from the PDC connector receptacle. 7. Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4748 Battery and Generator Connections to PDC 8. Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud. 9. Remove the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC and remove the eyelet from the stud. Power Distribution Center Remove/Install 10. Remove the screw that secures the PDC housing to the left front fender wheel housing. 11. Disengage the latches for the two PDC mounts and lift the unit off of the battery tray stanchions. 12. Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center (PDC) <--> [Electrical Accessory Panel] > Component Information > Diagrams > Page 4749 INSTALLATION NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. 1. Position the PDC and the headlamp and dash wire harness unit in the engine compartment. 2. Install the two PDC mounts onto the two stanchions of the battery tray. 3. Install and tighten the screw that secures the PDC housing to the left front fender wheel housing. Tighten the screw to 7.9 Nm (70 in. lbs.). 4. Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC. 5. Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 6. Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC, 7. Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 Nm (80 in. lbs.). 8. Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip. 9. Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle. 10. Install and latch the cover onto the PDC. 11. Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. 12. Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. 13. Reconnect each of the headlamp and dash wire harness connectors. 14. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block Fuse: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Junction Block > Page 4754 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block Fuse: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4757 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4758 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4759 Fuse: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4760 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4761 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4762 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4763 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4764 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4765 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4766 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4767 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4768 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Junction Block > Page 4769 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block Fuse: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Junction Block > Page 4772 Fuse: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Page 4773 Fuse: Description and Operation GENERATOR CARTRIDGE FUSE A 140 ampere generator cartridge fuse is used on this model. The generator cartridge fuse is similar to other cartridge fuses found in the Power Distribution Center (PDC). This fuse has a color-coded plastic housing and a clear plastic fuse conductor inspection cover like other cartridge fuses, but has a higher current rating and is connected and secured with screws instead of being pushed onto male spade-type terminals. The generator cartridge fuse cannot be repaired and, if faulty or damaged, it must be replaced. The generator cartridge fuse is secured between the two B(+) terminal stud connection bus bars within the Power Distribution Center (PDC). This fuse protects the vehicle electrical system from damage that could be caused by excessive charging system output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC. If a generator cartridge fuse fails, be certain to completely inspect and test the vehicle charging system before replacing the fuse and returning the vehicle to service. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Page 4774 Fuse: Service and Repair Generator Cartridge Fuse If a generator cartridge fuse fails, be certain to inspect and test the vehicle charging system before replacing the cartridge fuse and returning the vehicle to service. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unlatch and remove the cover from the Power Distribution Center (PDC). 3. Remove the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. 4. Remove the generator cartridge fuse from the PDC. INSTALLATION 1. Position the generator cartridge fuse onto the two B(+) terminal stud bus bars within the PDC. 2. Install and tighten the two screws that secure the generator cartridge fuse to the two B(+) terminal stud bus bars within the PDC. Tighten the screws to 3.4 Nm (30 in. lbs.). Be certain that both screws are tightened to the proper torque value. 3. Install and latch the cover onto the PDC. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block Fuse Block: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Junction Block > Page 4779 Fuse Block: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Fuse Block: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Fuse Block: Connector Views Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 8w-12-4 Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Fuse Block: Electrical Diagrams 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 8w-12-3 Fuse/Relay Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 8w-11-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 8w-11-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 8w-11-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 8w-11-6 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 8w-12-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 8w-12-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 8w-12-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 8w-12-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 8w-12-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 8w-12-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 8w-12-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 8w-12-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 8w-12-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 8w-12-14 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 8w-12-15 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 8w-12-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4835 Fuse Block: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Junction Block > Page 4838 Fuse Block: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4839 Fuse Block: Description and Operation JUNCTION BLOCK Junction Block Location An electrical Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. The JB serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The JB houses up to nineteen blade-type fuses (two standard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as an adhesive- backed fuse layout map to ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged; the entire JB unit must be replaced. All of the circuits entering and leaving the JB do so through up to nine wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. RELAY AND FUSE BLOCK Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4840 Relay And Fuse Block Location The relay and fuse block is snap fit onto mounting tabs located on the end of the Junction Block (JB) nearest to the dash panel, under the left outboard end of the instrument panel. The relay and fuse block provides additional capacity for distribution and control of electrical current for some of the accessory systems that are unique to this vehicle, and which could not be accommodated by the JB or the Power Distribution Center (PDC). The relay and fuse block has cavities for up to four additional blade-type mini fuses, the electronic combination flasher, and three additional International Standards Organization relays (one standard-type and two micro-type). The relay and fuse block components are accessed for service by removing the steering column opening cover from the instrument panel. The relay and fuse block is then disengaged from the JB mounting tabs and pulled out from under the instrument panel. Service replacement of the relay and fuse block unit requires instrument panel assembly removal. The relay and fuse block unit cannot be repaired and is only serviced as a unit with the instrument panel wire harness assembly. If the relay and fuse block housing or its internal circuits are faulty or damaged, the entire instrument panel wire harness unit must be replaced. The relay and fuse block is integral to the instrument panel wire harness, and all circuits entering or leaving this module do so through the instrument panel wire harness. Internal connection of all of the relay and fuse block circuits is accomplished by hard wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block Fuse Block: Service and Repair Fuse/Relay Block The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel wire harness unit must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the dash panel. 3. Disconnect each of the instrument panel wire harness connectors. 4. Remove all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Disengage each of the retainers that secure the instrument panel wire harness to the instrument panel components. Relay and Fuse Block Remove/Install 6. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the Junction Block (JB). 7. Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit. INSTALLATION NOTE: If the relay and fuse block is being replaced with a new unit, be certain to transfer each of the fuses, the flasher and the relays from the faulty relay and fuse block to the proper cavities of the replacement relay and fuse block. 1. Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. 2. Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB). 3. Engage each of the retainers that secure the instrument panel wire harness to the instrument panel components. 4. Install all of the fasteners that secure each of the instrument panel wire harness ground eyelets to the instrument panel components. 5. Reconnect each of the instrument panel wire harness connectors. 6. Install the instrument panel assembly onto the dash panel. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 4843 Fuse Block: Service and Repair Junction Block Replacement WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE,THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Fuse Access Panel Remove/Install 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Reach through the instrument panel fuse access panel opening to access and remove the one screw that secures the Junction Block (JB) to the left instrument panel end bracket. 4. Remove the steering column opening cover from the instrument panel. Junction Block Remove/Install 5. Reach through the outboard side of the instrument panel steering column opening to access and disconnect all of the wire harness connectors from the JB connector receptacles. 6. Reach through the outboard side of the instrument panel steering column opening to access and remove the relay and fuse block from the JB. Push the relay and fuse block towards the left end of the instrument panel to disengage its mounting slots from the tabs on the JB. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse/Relay Block > Page 4844 7. Reach through the outboard side of the instrument panel steering column opening to access and remove the one screw that secures the JB to the left instrument panel end bracket. 8. Reach through the outboard side of the instrument panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block for the location of complete circuit diagrams and cavity assignments for the JB. 1. Reach through the outboard side of the instrument panel steering column opening to position the JB onto the left instrument panel end bracket. 2. Reach through the outboard side of the instrument panel steering column opening to install and tighten the one screw that secures the JB to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reach through the outboard side of the instrument panel steering column opening to access and install the relay and fuse block onto the JB by engaging the relay and fuse block mounting slots with the tabs on the JB. 4. Reach through the outboard side of the instrument panel steering column opening to access and reconnect all of the wire harness connectors to the JB connector receptacles. 5. Install the steering column opening cover onto the instrument panel. 6. Reach through the instrument panel fuse access panel opening to install and tighten the one screw that secures the junction block to the left instrument panel end bracket. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4849 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4850 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Joint Connector 1 > Page 4851 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4855 Ignition Off-Draw (IOD) Fuse: Service and Repair Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the Oft position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. REMOVAL 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4861 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4864 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4865 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4866 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4867 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4868 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4869 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4870 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4871 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4872 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4873 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4874 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4875 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4876 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4879 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block Relay Box: Locations Junction Block Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block > Page 4884 Relay Box: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4887 8w-12-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4888 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4889 Relay Box: Diagrams Power Distribution Center 8w-10-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4890 8w-10-3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4891 8w-10-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4892 8w-10-5 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4893 8w-10-6 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4894 8w-10-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4895 8w-10-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4896 8w-10-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4897 8w-10-10 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4898 8w-10-11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 4899 8w-10-12 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block Relay Box: Application and ID Junction Block Junction Block Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block > Page 4902 Relay Box: Application and ID Power Distribution Center Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation Ignition Off-Draw (IOD) Fuse: Description and Operation Ignition-Off Draw Fuse - Typical All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block (JB) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the JB as part of the preparation procedures performed just prior to new vehicle delivery. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed to provide service access to the fuses in the JB. A finger recess is molded into the access panel for easy removal. An adhesive-backed fuse layout map is secured to the instrument panel side of the access panel to ensure proper fuse identification. The IOD fuse is a 15 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its JB cavity, and as a fuse holder that conveniently stores the fuse in the same JB cavity after it has been disconnected. The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the OFF position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the OFF position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Ignition Off-Draw (IOD) Fuse <--> [Power Interrupt Connector/Switch] > Component Information > Description and Operation > Page 4907 Ignition Off-Draw (IOD) Fuse: Service and Repair Ignition-Off Draw Fuse - Typical The Ignition-Off Draw (IOD) fuse is disconnected from Junction Block (JB) fuse cavity 12 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the OFF position. Failure to place the ignition switch in the Oft position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the OFF position will usually correct the scrambled radio display condition. REMOVAL 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. Grasp the upper and lower tabs of the IOD fuse holder unit in fuse cavity 12 of the JB between the thumb and forefinger and pull the unit firmly outward. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. INSTALLATION 1. Turn the ignition switch to the OFF position. 2. Remove the fuse access panel by unsnapping it from the left outboard end of the instrument panel. 3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity 12 firmly into the JB. 4. Install the fuse access panel by snapping it onto the left outboard end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications 2WD Caster (+- 0.50 Deg.) Preferred 3.10 deg Max Allowable R/L Diff erence 0.50 deg Camber (+- 0.50 Deg.) Preferred -0.25 deg Max Allowable R/L Diff erence 0.50 deg Total Toe (+- 0.06 Deg.) Preferred 0.10 deg Max Allowable R/L Diff erence 0.06 deg Thrus Angle (+- 0.40 Deg.) 0.00 deg 4WD Caster (+- 0.50 Deg.) Preferred 3.30 deg Max Allowable R/L Diff erence 0.50 deg Camber (+- 0.50 Deg.) Preferred -0.25 deg Max Allowable R/L Diff erence 0.50 deg Total Toe (+- 0.06 Deg.) Preferred 0.10 deg Max Allowable R/L Diff erence 0.06 deg Thrus Angle (+- 0.40 Deg.) 0.00 deg Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4912 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rubber bushings must never be lubricated. Refer to Maintenance for the recommended maintenance schedule. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Part 1 Of 2 Part 2 Of 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4915 SUSPENSION AND STEERING SYSTEM DIAGNOSIS CHARTS Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4916 Alignment: Service and Repair Wheel Alignment Wheel Alignment Setup WHEEL ALIGNMENT NOTE: 4x4 suspension height measurement must be performed before alignment. CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. NOTE: On 4x2 vehicles use Alignment Tool 8393 for alignment. The tool attaches to the pivot bar on the upper control arm. Camber Move the front of the pivot bar in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the pivot bar nuts to proper torque specification. Caster Moving the rear position of the pivot bar in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the pivot bar in or out. Then move the front of the pivot bar slightly in the opposite direction. To increase positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. Toe Adjustment The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 4917 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs. ). 5. Verify the specifications. 6. Turn off engine. Wheel Alignment Specifications Chart NOTE: All alignment specifications are in degrees. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 4922 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor, Refer to Brakes and Traction Control. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. 10. Remove the upper ball joint nut and separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When install Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball joints and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ABS speed sensor, brake dust shield, rotor and caliper. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4928 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4929 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4930 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4931 Power Steering Fluid: Specifications All models Mopar Power Steering Fluid or equivalent Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4932 Power Steering Fluid: Service Precautions DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage can result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Lines to Rack Pressure Line 25 ft.lb Return Line 25 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4940 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4941 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4942 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4945 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Engine Relief Pressure (+- 50 psi) Flow Rate (At 1500 RPM) 5.2L 1500 psi 2.4 - 2.8 gal/min 4.7L 1450 psi 2.4 - 2.8 gal/min 5.9L 1500 psi 2.4 - 2.8 gal/min Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4946 Power Steering Pump: Description and Operation DESCRIPTION The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. Trailer tow option vehicles are equipped with a power steering pump oil cooler. On the 5.2L and 5.9L the oil cooler is mounted to the engine block. On the 4.7L the oil cooler is mounted to the power steering pump. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump and. The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4947 Power Steering Pump: Testing and Inspection The pump is serviced as an assembly and should not be disassembled. Plastic pump reservoirs can be replace and the reservoir O-ring. Check for leaks in the following areas: Pump shaft seal behind the pulley - Pump to reservoir O-ring - Reservoir cap - Pressure and return lines - Flow control valve fitting Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Initial Operation STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. CAUTION: Use MOPAR Power Steering Fluid or equivalent. Do not use automatic transmission fluid and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Turn steering wheel all the way to the left 2. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two 2 minutes. 3. Raise the front wheels off the ground. 4. Slowly turn the steering wheel lock-to-lock 20 times with the engine off while checking the fluid level. NOTE: Vehicles with long return lines or oil coolers turn wheel 40 times. 5. Start the engine. With the engine idling maintain the fluid level. 6. Lower the front wheels and let the engine idle for two minutes. 7. Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Removal and Installation REMOVAL 1. Remove the serpentine drive belt, refer to Engine, Drive Belts, Mounts, Brackets and Accessories, Drive belts for procedures. 2. Clamp the fluid return hose and disconnect the hoses from the power steering pump. Cap the fittings. 3. Remove battery ground cable and bracket bolts. 4. Remove the pump assembly. 5. Remove the pump pulley, refer to Power Steering Pump Pulley, Service and Repair for removal procedures. This will allow access to the pump attaching screws. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4950 6. Remove the pump bracket bolts and remove the bracket. INSTALLATION 1. Install the bracket on the pump and tighten bolts to 41 Nm (30 ft. lbs.). 2. Install the pump pulley. 3. Install pump assembly on the engine block and tighten the bolts to 41 Nm (30 ft. lbs.). 4. Install the battery ground wire and tighten nut to 41 Nm (30 ft. lbs.). 5. Connect the fluid hoses to the pump. 6. Install the serpentine drive belt. 7. Fill the reservoir with power steering fluid and perform Power Steering Pump Initial Operation. See: Initial Operation Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 4951 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333. INSTALLATION 1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-B flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 minutes) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 4952 Power Steering Pump: Tools and Equipment SPECIAL TOOLS Special Tool 6815 Special Tool 6893 Special Tool C-4333 Special Tool C-4063B Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 4957 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair STEERING COLUMN OPENING COVER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Fig. 14 2. Reach under the left end of the instrument panel to access and unsnap the rod end clip on the park brake release link and disengage the link from the back of the handle (Fig. 14). 3. Remove the three screws that secure the lower edge of the steering column opening cover to the instrument panel structural support. Fig. 15 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 4961 4. Using a trim stick C-4755 or equivalent, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column away from the instrument panel far enough to disengage each of the snap clip retainers from their receptacles in the instrument panel base trim (Fig. 15). 5. Remove the steering column opening cover from the instrument panel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the steering column opening cover to the instrument panel (Fig. 15). 2. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel base trim. 3. Using hand pressure, press firmly on the steering column opening cover over the snap clip locations until each of the snap clips is fully engaged in its receptacle. 4. Install the three screws that secure the lower edge of the steering column opening cover to the instrument structural support (Fig. 14). 5. Reach under the left end of the instrument panel to access and engage the park brake release link to the back of the handle. Then snap the rod end clip over the park brake release link to secure the connection. 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4965 Steering Gear: Description and Operation DESCRIPTION A rack and pinion steering gear is made up of two main components, the pinion shaft and the rack. The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. If a boot seal becomes damaged, the steering gear must be removed to replace the boot seal. OPERATION The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts from the tie rod ends. 3. Separate tie rod ends from the knuckles with Puller C-3894-A. 4. Remove the power steering lines from the gear. 5. Remove the lower coupler bolt and slide the coupler off the gear. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4968 6. Remove the mounting bolts from the gear to the front crossmember and remove the gear. INSTALLATION NOTE: Before installing gear inspect bushings and replace if worn or damaged. 1. Install gear on front crossmember and tighten mounting bolts to 258 Nm (190 ft. lbs.). 2. Slide shaft coupler onto gear. Install new bolt and tighten to 49 Nm (36 ft. lbs.). 3. Clean tie rod end studs and knuckle tapers. 4. Install tie rod ends into the steering knuckles and tighten the nuts to 108 Nm (80 ft. lbs.). 5. Install power steering lines to steering gear. 6. Remove support and lower vehicle. 7. Fill system with fluid and perform Power Steering Pump Initial Operation. 8. Adjust the toe position, refer to Wheels, Tires and Alignment, Alignment, Adjustment for procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 4969 Steering Gear: Service and Repair Disassembly and Assembly REMOVAL 1. Remove steering gear. 2. Loosen the jam nut then remove the tie rod end and jam nut. 3. Remove the outer clamp from the rubber boot. 4. Remove the boot inner clamp. 5. On 4x2 vehicles mark the breather tube location on steering gear before removing the rubber boot. INSTALLATION 1. Lubricate the boot outer groove (tie rod) with silicone type lubricant. Ensure that the boot is not twisted. 2. On 4x2 vehicles align the breather tube with the reference mark on the steering gear. 3. Position and align the new boot over the housing. 4. Install inner clamp on the rubber boot. 5. Install the snorkel clamp on 4x2 vehicles. 6. Install outer clamp on the inner tie rod. 7. Install the jam nut and the tie rod end. 8. Install steering gear. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 4970 Special Tool C-3894_A Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Nut 35 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 4974 Steering Wheel: Service and Repair WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED, REFER TO RESTRAINT SYSTEMS FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. CAUTION: All fasteners must be torqued to specification to ensure proper operation of the steering column. REMOVAL 1. Position front wheels straight ahead. 2. Remove the negative (ground) cable from the battery. 3. Remove the airbag. Refer to Restraint Systems. See: Restraint Systems/Air Bag Systems/Air Bag 4. Remove the steering wheel with an appropriate puller. CAUTION: Ensure the puller bolts are fully engaged into the steering wheel and not into the clockspring, before attempting to remove the wheel. Failure to do so may damage the steering wheel/clockspring. INSTALLATION 1. Install steering wheel and tighten nut to 47 Nm (35 ft. lbs.). 2. Install airbag. Refer to Restraint Systems for procedure. See: Restraint Systems/Air Bag Systems/Air Bag 3. Connect the battery ground (negative) cable. 4. Check operation of the automatic transmission shift linkage and adjust as necessary. Refer to Transmission and Drivetrain for adjustment procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Knuckle Nut 80 ft.lb Jam Nut 55 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4979 Tie Rod End: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the nut from the tie rod end. 3. Separate the tie rod end from the steering knuckle with Puller C-3894-A. 4. Loosen the jam nut and unthread the tie rod end. INSTALLATION 1. Thread the tie rod end onto the tie rod. 2. Clean the tie rod end stud and knuckle taper. 3. Install the tie rod end stud into the steering knuckle and tighten the nut to 108 Nm (80 ft. lbs.). 4. Tighten the jam nut to 75 Nm (55 ft. lbs.). NOTE: Do not twist boot while tighten the jam nut. 5. Remove support and lower vehicle. 6. Adjust the wheel toe position, refer to Wheels, Tires and Alignment, Alignment, Adjustment for procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. Ball Joint: Technical Service Bulletins Suspension - Upper Ball Joint Replacement/Warranty Ext. NUMBER: 02-010-04 GROUP: Suspension DATE: December 16, 2004 SUBJECT: Upper Ball Joint Extended Warranty OVERVIEW: This bulletin involves inspecting and if necessary replacing the upper ball joints. NOTE: The upper ball joint warranty period has been extended to 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details. MODELS: 2000 - 2003 (AN) Dakota 4x2 2000 - 2003 (DN) Durango 4x2 NOTE: This bulletin applies only to the above vehicles built through December 31, 2002 (MDH 1231XX). DIAGNOSIS: 1. Position a floor jack under the right side lower suspension arm. 2. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 4985 3. Mount a dial indicator (Special Tool C3339 or equivalent) solidly on the upper suspension arm (Fig. 1). 4. Position the dial indicator plunger against the back side of the steering knuckle boss for the upper ball joint (Fig. 1). 5. Zero the dial indicator while pulling outward on the top of the tire. 6. While an assistant watches the dial indicator gauge, grasp the top of the tire and push inward. Record the dial indicator reading observed from the full outward to full inward position. 7. Repeat Step #1 through Step # 6 on the left side upper ball joint. When both the left and the right upper ball joints have been inspected, proceed to Step # 8. 8. Based on the results recorded in Step # 6: a. If the lateral movement on both upper ball joints is less than 0.060 in. (1.52 mm), no further action is required. Remove the dial indicator, lower the wheel and return the vehicle to the owner. b. If the lateral movement on either of the upper ball joints is greater than 0.060 in. (1.52 mm), replace both upper ball joints as described in the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 4986 SPECIAL TOOLS/EQUIPMENT REQUIRED: PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Position a hydraulic jack under the left side lower control arm and raise the jack to unload the rebound bumper. 4. Remove the cotter pin from the upper ball joint castle nut. 5. Remove the upper ball joint castle nut from the upper ball joint stud. 6. Using a die grinder equipped with a cut-off wheel, grind an "X" through each of the three upper ball joint rivet heads (Fig. 2). CAUTION: Do not grind into the control arm. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 4987 7. Using an air chisel, chisel the three rivet heads off of the upper ball joint. 8. Punch out the rivets using a drift and hammer. 9. Separate the upper ball joint from the steering knuckle with special tool MB991113. 10. Remove and discard the old ball joint. 11. Using 100 grit emery cloth, lightly sand the top surface of the steering knuckle to remove any rust and/or scale from the steering knuckle (Fig. 3). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Suspension - Upper Ball Joint Replacement/Warranty Ext. > Page 4988 12. Insert the bolts supplied with the ball joint package from the bottom side of the control arm (Fig. 4). 13. Place the new ball joint onto the control arm and install retaining nuts (Fig. 4). Tighten the nuts to 50 ft. lbs. (68 N.m). 14. Position the steering knuckle onto the upper ball joint stud. 15. Install the castle nut onto the ball joint stud. Tighten the upper ball joint castle nut to 60 ft. lbs. (81 N.m). NOTE: If the castle nut slots do not line up with the cotter pin hole in the ball joint stud, continue tightening the nut until the next set of castle nut slots line up with the cotter pin hole. Do not loosen the nut. 16. Install a new cotter pin through the castle nut and secure it by bending the arms of the pin. 17. Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs (135 N.m). 18. Repeat Step # 3 through Step # 17 on the right side of the vehicle. 19. Lower the vehicle. 20. Place the vehicle on an alignment rack and set toe to +0.10 degrees (+/- 0.06 degrees). POLICY: Reimbursable within the provisions of the extended warranty period of 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Page 4989 Ball Joint: Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................................... 0.060" Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint 1. Raise the front of the vehicle. Place safety floor stands under both lower suspension arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. NOTE: The upper suspension arms must not contact the rebound bumpers. 2. Remove the tire and wheel assemblies. 3. Mount a dial indicator solidly under the lower suspension arm. 4. Position indicator plunger against the bottom of the steering knuckle lower ball joint boss. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle lower ball joint boss. 5. Position a pry bar over the top of the upper suspension arm and under the pivot bar of the upper suspension arm. Pry down on the upper suspension arm and then zero the dial indicator. 6. Reposition the pry bar under the upper suspension arm and on top of the frame rail. Pry up on the upper suspension arm and record the dial indicator reading. 7. If the travel exceeds 1.52 mm (0.060 inch), replace the lower suspension arm. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 4992 Ball Joint: Testing and Inspection Upper Ball Joint 1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). 2. Mount a dial indicator solidly on the upper suspension arm. 3. Position the indicator plunger against the upper ball joint boss of the steering knuckle. 4. Grasp the top of the tire and apply force in and out. Look for movement at the ball joint between the upper suspension arm and steering knuckle. 5. If lateral movement is greater than 1.52 mm (0.060 inch), replace upper suspension arm. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service Control Arm Bushing: Technical Service Bulletins Upper Control Arm - Bushing Service NUMBER: 02-006-00 GROUP: Suspension DATE: Oct. 27, 2000 SUBJECT: Upper Control Arm Bushing Service OVERVIEW: This bulletin provides service procedures for the removal and installation of the upper control arm bushing. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES. DISCUSSION: It is no longer necessary to replace the upper control arm assembly to service just the upper control arm bushings. Upper control arm bushing p/n 52037673 is now available through Mopar. The following Repair Procedure provides upper control arm bushing removal and installation information. Special Tool 8441 is required to remove and install upper control arm bushings and is now available through Miller Special Tools. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: UPPER CONTROL ARM BUSHING REMOVAL 1. Remove the control arm from the vehicle. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, REMOVAL AND INSTALLATION - UPPER SUSPENSION ARM - REMOVAL. 2. Mount the control arm securely in a vise. 3. Remove the nut and washer from the upper control arm pivot bar shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service > Page 4998 4. Install Special Tool 8441, Upper Control Arm Bushing Remover/Installer (Fig. 1). 5. Press out the old bushings. UPPER CONTROL ARM BUSHING INSTALLATION 1. Slide the bushing over the pivot bar shaft and insert it into the control arm. 2. Install Special Tool 8441, Upper Control Arm Bushing Remover/Installer (Fig. 2). 3. Press the bushing into the control arm. 4. Install the washer and nut onto the upper control arm pivot bar shaft. Tighten the nut to 167 Nm (130 ft. lbs.). CAUTION: ENSURE THAT THE SELF-LOCKING FEATURE OF THE NUT IS STILL FUNCTIONAL. REPLACE THE NUT ANYTIME THE SELF-LOCKING FEATURE DOES NOT FUNCTION AS DESIGNED. 5. Remove the control arm from the vise. 6. Install the control arm in the vehicle. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, - REMOVAL AND INSTALLATION - UPPER SUSPENSION ARM - INSTALLATION. 7. Align the front suspension. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, ALIGNMENT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service > Page 4999 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates Cross-Member: Technical Service Bulletins Engine/Electrical - Torque Spec/Schematic Updates NUMBER: 26-02-00D GROUP: Miscellaneous DATE: April, 2000 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 2000 Durango Service Manual - Publication Number 81-370-0016 DESCRIPTION OF CHANGES Updates to the wiring schematic Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5004 8W-30-25 Updates to the engine support & crossmember torque specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5005 9-29 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5006 9-81 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5007 9-102 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5008 9-132 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5009 9-160 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5010 9-161 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5011 1-189 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 5012 Cross-Member: Technical Service Bulletins Transmission Crossmember - Service Precautions NUMBER: 13-002-00 GROUP: Frame And Bumpers DATE: Oct. 27, 2000 SUBJECT: Transmission Crossmember Service MODELS: 2000 - 2001 (AN) Dakota 2000 - 2001 (DN) Durango DISCUSSION: The fasteners that retain the transmission crossmember to the frame utilize a thread lock patch on the threads of the fastener. The thread lock patch is required to help prevent the fastener from loosening during normal vehicle usage. When the transmission crossmember is required to be removed during service, the amount of thread patch material on the fastener will deteriorate during fastener removal. To ensure that the fastener retention is not compromised after service, the transmission crossmember fastener threads must have Mopar Lock & Seal p/n 04318031 added to the threads of each fastener. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5016 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor, Refer to Brakes and Traction Control. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. 10. Remove the upper ball joint nut and separate the ball joint from the knuckle with Remover MB-991113. CAUTION: When install Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball joints and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ABS speed sensor, brake dust shield, rotor and caliper. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Description and Operation Rear Knuckle: Description and Operation Refer to Steering, Steering Knuckle, Description and Operation for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Description and Operation > Page 5020 Rear Knuckle: Service and Repair Refer to Steering, Steering Knuckle, Service and Repair for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications > Front Stabilizer Bar: Specifications Stabilizer Bar Link Upper Nut 27 ft.lb Link Ball Stud Nut 35 ft.lb Retainer Bolts 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications > Front > Page 5025 Stabilizer Bar: Specifications Stabilizer Bar Link Upper Nut 70 ft.lb Link Lower Nut 50 ft.lb Retainer Bolts 40 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front Stabilizer Bar: Description and Operation Front DESCRIPTION The bar extends across the front underside of the chassis and mounts on the frame rails. Links connected the bar to the lower suspension arms. Stabilizer bar mounts are isolated by rubber bushings. Links are isolated with rubber grommets. OPERATION The stabilizer bar is used to minimize vehicle front sway during turns. The spring steel bar helps to control the vehicle body in relationship to the suspension. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Description and Operation > Front > Page 5028 Stabilizer Bar: Description and Operation Rear DESCRIPTION The stabilizer bar extends across the underside of the vehicle and is bolted to the top of the axle. Links at the end of the bar are bolted to the frame. OPERATION The stabilizer bar is used to minimize vehicle body roll. The spring steel bar helps to control the vehicle body in relationship to the suspension. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front REMOVAL 1. Raise and support the vehicle. 2. Remove the upper link nut, retainer and grommet from each link. 3. Remove the lower link nut from the lower suspension arm on each side. 4. Remove the stabilizer bar retainer bolts and remove the retainers and stabilizer bar from the vehicle. 5. Remove the bushings from the stabilizer bar. INSTALLATION 1. Install the bushings on the stabilizer bar. 2. Install the stabilizer bar on the frame and install the retainers and the bolts. 3. Tighten the bolts to 60 Nm (45 ft. lbs.). NOTE: Ensure the bar is center with equal spacing on both sides. 4. Install the link lower retainer and grommet on the links. 5. Install the links into the stabilizer bar and lower suspension arm on each side. 6. Install the lower link mounting nut and tighten to 47 Nm (35 ft. lbs.). NOTE: Ensure both link end caps are facing straight forward. 7. Install the upper link grommet, retainer and nut and tighten to 37 Nm (27 ft. lbs.). 8. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5031 Stabilizer Bar: Service and Repair Rear REMOVAL 1. Raise and support vehicle. 2. Remove links upper mounting nuts and bolts. 3. Remove the cotter pins and nuts from the links at the stabilizer bar. 4. Separate the links from the stabilizer bar with Puller C-3894-A and remove the links. 5. Remove stabilizer bar retainer bolts and retainers. 6. Remove Stabilizer bar and remove bushings. INSTALLATION 1. Install stabilizer bar bushings. 2. Install the stabilizer bar and center it with equal spacing on both sides. 3. Install stabilizer bar retainers and tighten bolts to 54 Nm (40 ft. lbs.). 4. Install link on the frame and the stabilizer bar. Install mounting bolts and nuts. 5. Remove support and lower vehicle. 6. Tighten stabilizer link upper nuts to 95 Nm (70 ft. lbs.). 7. Tighten stabilizer link lower nuts to 68 Nm (50 ft. lbs.) and install a new cotter pin. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-02-00A > Jul > 00 > Suspension - Driveline Drone/Vibration Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Driveline Drone/Vibration NUMBER: 02-02-00A GROUP: Suspension DATE: July 7, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-00, DATED APRIL 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED PART NUMBERS. SUBJECT: 40-48 KPH (25-30 MPH) Driveline Drone/Vibration OVERVIEW: This bulletin involves installing revised rear leaf springs. MODELS: 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X4 VEHICLES BUILT BEFORE NOVEMBER 22, 1999 (MDH 1122XX) AND 4X2 VEHICLES BUILT BEFORE NOVEMBER 29, 1999 (MDH 1129XX). SYMPTOM/CONDITION: Customers may complain that while driving on a smooth road, they hear a drone/vibration that occurs between 40-48 kph (25-30 mph). In some cases, the drone/vibration resonance may cause the instrument panel to buzz. DIAGNOSIS: Drive the vehicle on a smooth paved road. Accelerate the vehicle to 56 kph (35 mph). If the driveline drone/vibration starts to occur at/or close to 40 kph (25 mph) and is gone by the time 48 kph (30 mph) is reached, perform the Repair Procedure. If the drone/vibration occurs before 40 kph (25 mph) or occurs after 48 kph (30 mph), further diagnosis is required. NOTE: IF CONDITIONS DO NOT ALLOW THE ROAD TEST TO BE PERFORMED PROPERLY, PERFORM THE REPAIR PROCEDURE IF THE CUSTOMER's DESCRIPTION OF THE CONCERN MATCHES THE DESCRIPTION IDENTIFIED IN SYMPTOM/CONDITION. PARTS REQUIRED: AR (2) **52106831AG** Spring, Rear Leaf, 4X2 Vehicles AR (2) **52106830AG** Spring, Rear Leaf, 4X4 Vehicles 4 **52039305** U-Bolt 8 06502698 Nut, U-Bolt REPAIR PROCEDURE: 1. Remove both rear leaf spring assemblies and replace them with new springs (see Parts Required section). Refer to the 2000 Durango Service Manual (Publication No. 81-370-0016), pages 2-25 and 2-26 for information regarding Removal and Installation procedures for the rear Leaf Springs. NOTE: THE U-BOLTS AND U-BOLT RETAINING NUTS MUST NOT BE REUSED. ALWAYS INSTALL NEW U-BOLTS AND NUTS WHEN REPLACING REAR LEAF SPRINGS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-01-91 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-02-00A > Jul > 00 > Suspension - Driveline Drone/Vibration > Page 5040 Disclaimer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): Customer Interest Rear Leaf Springs - Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5045 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5046 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5047 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5048 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5049 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5050 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5051 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5052 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-02-00A > Jul > 00 > Suspension - Driveline Drone/Vibration Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Driveline Drone/Vibration NUMBER: 02-02-00A GROUP: Suspension DATE: July 7, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-00, DATED APRIL 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED PART NUMBERS. SUBJECT: 40-48 KPH (25-30 MPH) Driveline Drone/Vibration OVERVIEW: This bulletin involves installing revised rear leaf springs. MODELS: 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X4 VEHICLES BUILT BEFORE NOVEMBER 22, 1999 (MDH 1122XX) AND 4X2 VEHICLES BUILT BEFORE NOVEMBER 29, 1999 (MDH 1129XX). SYMPTOM/CONDITION: Customers may complain that while driving on a smooth road, they hear a drone/vibration that occurs between 40-48 kph (25-30 mph). In some cases, the drone/vibration resonance may cause the instrument panel to buzz. DIAGNOSIS: Drive the vehicle on a smooth paved road. Accelerate the vehicle to 56 kph (35 mph). If the driveline drone/vibration starts to occur at/or close to 40 kph (25 mph) and is gone by the time 48 kph (30 mph) is reached, perform the Repair Procedure. If the drone/vibration occurs before 40 kph (25 mph) or occurs after 48 kph (30 mph), further diagnosis is required. NOTE: IF CONDITIONS DO NOT ALLOW THE ROAD TEST TO BE PERFORMED PROPERLY, PERFORM THE REPAIR PROCEDURE IF THE CUSTOMER's DESCRIPTION OF THE CONCERN MATCHES THE DESCRIPTION IDENTIFIED IN SYMPTOM/CONDITION. PARTS REQUIRED: AR (2) **52106831AG** Spring, Rear Leaf, 4X2 Vehicles AR (2) **52106830AG** Spring, Rear Leaf, 4X4 Vehicles 4 **52039305** U-Bolt 8 06502698 Nut, U-Bolt REPAIR PROCEDURE: 1. Remove both rear leaf spring assemblies and replace them with new springs (see Parts Required section). Refer to the 2000 Durango Service Manual (Publication No. 81-370-0016), pages 2-25 and 2-26 for information regarding Removal and Installation procedures for the rear Leaf Springs. NOTE: THE U-BOLTS AND U-BOLT RETAINING NUTS MUST NOT BE REUSED. ALWAYS INSTALL NEW U-BOLTS AND NUTS WHEN REPLACING REAR LEAF SPRINGS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-01-91 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-02-00A > Jul > 00 > Suspension - Driveline Drone/Vibration > Page 5058 Disclaimer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Rear Leaf Springs Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5063 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5064 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5065 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5066 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5067 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5068 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5069 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 5070 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 5071 Suspension Spring ( Coil / Leaf ): Specifications Spring U-Bolt Nuts 90 ft.lb Spring Eye Nut 85 ft.lb Spring Shackle Nuts 85 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Leaf Spring Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Spring DESCRIPTION The rear suspension system uses multi-leaf single stage springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Leaf Spring > Page 5074 Suspension Spring ( Coil / Leaf ): Description and Operation Front DESCRIPTION The springs mount between the lower suspension arms and frame rail spring seats. A rubber isolator seats on top off the spring to help prevent noise. OPERATION The coil springs control ride quality and maintain proper ride height. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5075 Suspension Spring ( Coil / Leaf ): Testing and Inspection A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing rubber. If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips, and broken center bolts. Refer to Spring and Shock Absorber Diagnosis chart for additional information. SPRING AND SHOCK ABSORBER DIAGNOSTIC CHART Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Spring Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring REMOVAL 1. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove the stabilizer bar link from the lower suspension arm. 4. Remove the shock absorber. 5. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and upper shock mounting hole. 6. Tighten the tool lower nut to compress the coil spring. 7. Remove the lower ball joint nut and separate the ball joint from the knuckle with Remover C-4150A. 8. Loosen the spring compressor lower nut to relieve spring tension. 9. Remove the tool and pull down on the lower suspension arm to remove the spring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Spring > Page 5078 INSTALLATION NOTE: The ramped or open end of the coil spring is the bottom of the spring. 1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm pocket. Be sure that the coil spring is seated in the pocket. 2. Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring upper shock mounting hole. 3. Tighten the tool nut to compress the coil spring. 4. Install the lower ball joint into the knuckle and tighten the nut to 127 Nm (94 ft. lbs.). Install cotter pin. 5. Remove the spring compressor tool. 6. Install the stabilizer bar link to the lower suspension arm and tighten nut to 47 Nm (35 ft. lbs.). 7. Install the shock absorber. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Spring > Page 5079 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. REMOVAL 1. Raise the vehicle at the frame. 2. Support the axle to relieve the weight of the axle from the springs. 3. Remove the wheel and tire assemblies. 4. Remove shocks from the spring plates. 5. Remove the nuts, the U-bolts and spring plate from the axle. 6. Remove the nut and bolt from the front spring eye. 7. Remove the nut and bolt form the rear spring eye. 8. Remove the spring from the vehicle. 9. Remove the shackle from the frame bracket. INSTALLATION 1. Install shackle on the frame bracket and install the nut and bolt finger tight. 2. Position the spring under the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align front spring eye with the bolt hole in the front frame bracket. Install the spring eye bolt and nut and tighten the spring eye nut finger-tight. 4. Align spring shackle eye with the bolt hole in the rear frame bracket. Install the bolt and nut and tighten the spring shackle eye nut finger-tight. 5. Install the spring seat, U-bolts, spring plate, and nuts. 6. Tighten the U-bolt nuts to 122 Nm (90 ft. lbs). 7. Install the shocks to the spring plates. 8. Install the wheel and tire assemblies. 9. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. 10. Tighten the spring eye pivot bolt nut and all shackle nuts to 115 Nm (85 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Spring > Page 5080 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing DISASSEMBLE 1. Remove the spring from the vehicle. 2. Position the spring eye in a press. 3. Press the bushing out with an appropriate size driver. ASSEMBLE 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Install the spring on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Shock Absorber Upper Nut 19 ft.lb Lower Bolts 21 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 5085 Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Nut 70 ft.lb Upper Nut 70 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front DESCRIPTION The top of the low-pressure gas charged shock are bolted to the frame. The bottom of the shock are bolted to the lower suspension arm. OPERATION The shock absorbers dampen jounce and rebound of the vehicle over various road conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5088 Suspension Strut / Shock Absorber: Description and Operation Rear DESCRIPTION The top of the shock absorbers are bolted to the body crossmember. The bottom of the shocks are bolted to the axle brackets. OPERATION Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut / Shock Absorber: Testing and Inspection Front A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oilbase lubricants will deteriorate the bushing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5091 Suspension Strut / Shock Absorber: Testing and Inspection Rear Refer to Leaf Spring, Testing and Inspection, Procedures for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL 1. Remove the upper shock nut, retainer and grommet from the shock absorber stud. 2. Raise and support the vehicle. 3. Remove the lower mounting bolts and remove shock absorber through the lower suspension arm. INSTALLATION NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite 242 on existing nut. 1. Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud and extend the shock. Insert the shock absorber through the lower suspension arm and upper mounting hole. 2. Install the lower mounting bolts and tighten to 28 Nm (21 ft. lbs.). 3. Remove support and lower the vehicle. 4. Install the upper grommet and retainer (upper retainer is stamped with a U) on the shock absorber stud. Install a new nut or use Mopar Lock 'N Seal or Loctite 242 on existing nut and tighten to 26 Nm (19 ft. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5094 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Raise vehicle and support rear axle. 2. Remove shock absorber lower nut and bolt from the spring plate. 3. Remove shock absorber upper nut and bolt from the frame bracket and remove the shock absorber. INSTALLATION 1. Install shock absorber into upper frame bracket. Install bolt and nut and tighten nut to 95 Nm (70 ft. lbs.). 2. Install shock absorber into the spring plate. Install the bolt and nut and tighten nut to 95 Nm (70 ft. lbs.). 3. Remove axle support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Jounce Bumper Bolts 45 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5102 Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Wheel Hub, Service and Repair for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5105 Wheel Bearing: Service and Repair Rear For further information regarding this component and the system it is a part of, refer to Axle Shaft, Conventional Fixed/Floating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications Tire Size Manufacturer Revolutions Per Mile P235/75R15 XL MICHELIN 720 P235/75R15 XL GOODYEAR 729 P275/60R17 GOODYEAR 697 31x10.50R15 LT GOODYEAR 689 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire Tires: Description and Operation Tire DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown in Tire Rotation. This will help to achieve a greater tread life. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5116 Tires: Description and Operation Radial-Ply Tire DESCRIPTION Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 50 MPH is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5117 Tires: Description and Operation Replacement Tires DESCRIPTION The original equipment tires provide a proper balance of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5118 Tires: Description and Operation Tire Inflation Pressures DESCRIPTION Fig. 4 Under inflation will cause rapid shoulder wear, tire flexing, and Possible tire failure. Fig. 5 Over inflation will cause rapid center wear and loss of the tire's ability to cushion shocks. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the Tire Inflation Pressure Chart provided with the vehicles Owners Manual. A Certification Label on the drivers side door pillar provides the minimum tire and rim size for the vehicle. The label also list the cold inflation pressure for these tires at full load operation. Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure should be checked cold once a month. Tire pressure decreases as the ambient temperature drops. Check tire pressure frequently when ambient temperature varies widely. Tire inflation pressures are cold inflation pressure. The vehicle must sit for at least 3 hours to obtain the correct cold inflation pressure reading, or be driven less than one mile after sitting for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5119 Tires: Description and Operation Tire DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown in Tire Rotation. This will help to achieve a greater tread life. TIRE IDENTIFICATION Fig. 1 Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Radial-Ply Tire Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5120 DESCRIPTION Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 50 MPH is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Replacement Tires DESCRIPTION The original equipment tires provide a proper balance of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. Tire Inflation Pressures DESCRIPTION Fig. 4 Under inflation will cause rapid shoulder wear, tire flexing, and Possible tire failure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 5121 Fig. 5 Over inflation will cause rapid center wear and loss of the tire's ability to cushion shocks. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the Tire Inflation Pressure Chart provided with the vehicles Owners Manual. A Certification Label on the drivers side door pillar provides the minimum tire and rim size for the vehicle. The label also list the cold inflation pressure for these tires at full load operation. Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure should be checked cold once a month. Tire pressure decreases as the ambient temperature drops. Check tire pressure frequently when ambient temperature varies widely. Tire inflation pressures are cold inflation pressure. The vehicle must sit for at least 3 hours to obtain the correct cold inflation pressure reading, or be driven less than one mile after sitting for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Tire Pressure-High Speed Operation DESCRIPTION Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. For speeds up to and including 120 km/h (75 mph), tires must be inflated to the pressures shown on the tire placard. For continuous speeds in excess of 120 km/h (75 mph), tires must be inflated to the maximum pressure specified on the tire sidewall. Vehicles loaded to the maximum capacity should not be driven at continuous speeds above 75 mph (120 km/h). For emergency vehicles that are driven at speeds over 90 mph (144 km/h), special high speed tires must be used. Consult tire manufacturer for correct inflation pressure recommendations. Spare Tire - Temporary DESCRIPTION The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 MPH when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators Tires: Testing and Inspection Tread Wear Indicators Fig. 2 Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 5124 Tires: Testing and Inspection Tread Wear Patterns Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Pressure Gauges A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 5127 Tires: Removal and Replacement Fig. 7 For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area. The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. Fig. 1 All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 5131 Wheels: Testing and Inspection Inspect wheels for: Excessive runout - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: FAILURE TO USE EQUIVALENT REPLACEMENT WHEELS MAY ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE VEHICLE. USED WHEELS ARE NOT RECOMMENDED. THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE RIM COULD FAIL WITHOUT WARNING. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5136 Wheel Bearing: Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Refer to Wheel Hub, Service and Repair for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5139 Wheel Bearing: Service and Repair Rear For further information regarding this component and the system it is a part of, refer to Axle Shaft, Conventional Fixed/Floating. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub/Bearing Spindle Nut 185 ft.lb Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 5148 Wheel Fastener: Specifications Torque Specifications CAUTION: DO NOT USE CHROME PLATED LUG NUTS WITH CHROME PLATED WHEELS. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5149 Wheel Fastener: Service and Repair CAUTION: Do not use a hammer to remove wheel studs. REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper, caliper adapter and rotor, Refer to Brakes and Traction Control for procedure. Fig. 9 4. Remove stud from hub with Remover C-4150A. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor, caliper adapter. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications Air Door Actuator / Motor: Specifications Floor Defrost Door Actuator Mounting Screws 2.2 Nm Panel Defrost Door Actuator Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Page 5155 Air Door Actuator / Motor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Page 5156 Air Door Actuator / Motor: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Floor-Defrost Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Floor-Defrost Door Actuator Remove/Install 3. Unplug the two vacuum harness connectors from the floor-defrost door actuator. 4. Remove the push nut retainer that secures the floor-defrost door actuator link to the floor-defrost door crank arm. 5. Remove the two screws that secure the floor- defrost door actuator to the heater-A/C housing. 6. Disengage the floor-defrost door actuator link from the floor-defrost door crank arm and remove the actuator from the heater-A/C housing. 7. Reverse the removal procedures to install. Tighten the floor-defrost door actuator mounting screws to 2.2 Nm (20 in. lbs.). Panel-Defrost Door Actuator 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Page 5157 Panel-Defrost Door Actuator 3. Unplug the vacuum harness connector from the panel-defrost door actuator. 4. Remove the two screws that secure the panel-defrost door actuator to the heater-A/C housing. 5. Rotate the panel-defrost door actuator clockwise about one-quarter turn to disengage the hooked end of the actuator link from the hole on the end of the panel-defrost door lever. 6. Remove the panel-defrost door actuator from the heater-A/C housing. 7. Reverse the removal procedures to install. Tighten the panel-defrost door actuator mounting screws to 2.2 Nm (20 in. lbs.). Recirculation Air Door Actuator A recirculation air door and vacuum actuator are used only on models with the optional air conditioning system. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. If the vehicle is so equipped, and the heater- A/C housing is in its installed position in the vehicle, remove the Infinity speaker system amplifier. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Specifications > Page 5158 Recirculation Air Door Actuator Remove/Install 4. Unplug the two vacuum harness connectors from the recirculation air door actuator. 5. Remove the two stamped nuts that secure the recirculation air door actuator to the blower motor housing cover. 6. Unhook the actuator link from the recirculation air door lever. 7. Remove the actuator from the blower motor housing cover. 8. Reverse the removal procedures to install. Tighten the mounting nuts until the recirculation air door actuator is seated to the blower motor housing cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments Air Door Cable: Adjustments Any time the heater-A/C control or the temperature control cable are removed and/or replaced, the following procedure must be performed. 1. The temperature control cable housing and core must be installed at both the heater-A/C control and the heater-A/C housing ends, and the heater-A/C control must be installed in the instrument panel. 2. Rotate the temperature control knob on the heater-A/C control so that the knob pointer is in the 12 o'clock position. 3. Pull the temperature control knob straight out from the heater-A/C control base until the perimeter of the knob (not the knob pointer) protrudes about 6 mm (0.25 inch) from the face of the control base. 4. Rotate the temperature control knob to the 1 o'clock position. Push in on the knob slightly and continue rotating the knob to its full clockwise stop. The knob pointer should be aimed at a position about 8 mm (0.315 inch) beyond the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If the knob is not pointed to the correct position, go back to Step 2 and repeat the adjustment procedure. 5. Rotate the temperature control knob counter-clockwise until the knob pointer is in the 12 o'clock position again. 6. Push the temperature control knob straight in towards the heater-A/C control base until the perimeter of the knob (not the knob pointer) is flush with the face of the heater-A/C control base. 7. Rotate the knob to its full clockwise stop again. The knob pointer should be aimed at the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If OK, go to Step 8. If not OK, go back to Step 2. 8. Rotate the knob to its full counter-clockwise stop and release the knob. If the knob springs back from the counter-clockwise stop, the self-adjuster clip that secures the temperature control cable to the blend-air door lever is improperly installed. If the knob does not spring back, the temperature control cable adjustment is complete. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Page 5162 Air Door Cable: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Roll down the instrument panel assembly, but do not remove it from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Disconnect the temperature control cable from the heater-A/C control. Temperature Control Cable Remove/Install 4. Disconnect the temperature control cable housing flag retainer from the receptacle on the top of the heater-A/C housing. 5. Pull the temperature control cable core self-adjuster clip off of the pin on the end of the blend-air door lever. 6. Remove the temperature control cable from the vehicle. INSTALLATION Temperature Control Cable Self-Adjuster Clip Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Page 5163 Before installing the temperature control cable, be certain that the self-adjuster clip is properly positioned. This measurement must be made with the cable end bottomed against the flag retainer on the heater-A/C control end of the cable housing. The measurement is taken from the end of the flag retainer on the heater-A/C housing end of the cable to the center of the self-adjuster clip. If the self-adjuster clip is not properly positioned, slide the clip up or down the cable core as required to achieve the specified dimension. 1. Connect the temperature control cable to the heater-A/C control. 2. Route the cable through the instrument panel. Position the cable end near the connection points on the HVAC unit assembly, making sure not to kink or distort the cable. 3. Push the temperature control cable core self-adjuster clip onto the pin on the end of the blend-air door lever. 4. Snap the temperature control cable housing flag retainer into the receiver on the top of the heater-A/C housing. 5. Reinstall the instrument panel assembly. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 6. Connect the battery negative cable. 7. Adjust the temperature control cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions Air Duct: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5167 Air Duct: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Panel And Defroster Ducts The panel and defroster duets are integral to the instrument panel assembly. The defroster outlets are integral to the instrument panel top cover. Outlet Barrels In addition to the panel outlet barrels in the instrument panel, models equipped with the bucket seat option have two outlet barrels for the rear seat passengers located near the top of upper rear panel of the center floor console. The service procedures for all of these outlet barrels is the same. Models with the optional rear overhead A/C unit also have four outlet barrels located in the outlet bezel on the headliner, but these outlet barrels are only serviced as a unit with the rear overhead A/C outlet bezel. Outlet Barrels 1. Using a trim stick or another suitable wide- bladed flat tool, gently pry at the sides of the outlet barrels to release the snap-fit pivots on the barrel from the pivot pins in the outlet housing of the instrument panel top cover, the instrument cluster bezel or the center floor console. 2. To install the outlet barrel, position the barrel in the outlet housing and press inwards firmly and evenly until the barrel snaps into place. Front Seat Floor Duct Front Seat Floor Duct Remove/Install (Typical) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5168 1. Remove the three screws that secure the floor duct to the bottom of the heater-A/C housing. 2. Remove the floor duct from the heater-A/C housing. 3. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Rear Seat Floor Duct Control - Split Bench Seat Rear Seat Floor Duct Control - Split Bench Seat 1. Remove the three retainers that secure the HVAC rear bezel to the brackets near the back of the front seat center. 2. Pull the bezel away from the back of the front seat far enough to access and disengage the control cable retainer and cable end from the control. 3. Reverse the removal procedures to install. Rear Seat Floor Duct Control - Bucket Seat The rear floor duct control and linkage are only serviced as a unit with the console duct assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5169 Rear Seat Floor Duct Control - Bucket Seat 1. Remove the four screws that secure the console bin and remove the bin from the floor console. 2. Reach through the top of the console to disengage the control rod end from the floor duct damper door pivot. 3. Remove the floor console from the vehicle and disassemble as required to remove the console duct and control assembly from the console as a unit. 4. Reverse the removal procedures to install. Rear Seat Floor Duct The rear seat floor duct damper door is only serviced as part of the rear seat floor duct on bench seat models, or the center seat floor duct on bucket seat models. 1. Remove the carpeting from the floor panel transmission tunnel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5170 Rear Seat Floor Duct Remove/Install - Split Bench Seat Rear Seat Floor Duct Control - Bucket Seat 2. Remove the retainers that secure the ducts to the floor panel transmission tunnel. 3. Remove the duct(s) from the floor panel as required. 4. Reverse the removal procedures to install. Demister Duct Adapter 1. Roll the instrument panel assembly down, but do not remove it from the vehicle. 2. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater A/C housing. Rear Seat Floor Duct Remove/Install - Split Bench Seat 3. Remove the two screws that secure the demister duct adapter to the top of the heater-A/C housing. 4. Remove the demister duct adapter from the heater-A/C housing. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5171 Demister Hose 1. Remove the heater-A/C control from the instrument panel. 2. Reach through the heater-A/C control opening in the instrument panel to access and remove the screw that secures the flexible demister duct hose to the demister duct tee. 3. Roll the instrument panel assembly down, but do not remove it from the vehicle. 4. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 5. Remove the demister duct hose from the demister duct tee near the underside of the instrument panel top cover. 6. Reverse the removal procedures to install. Tighten the hose mounting screw to 2.2 Nm (20 in. lbs.). Demister Ducts And Outlets 1. Remove the instrument panel top cover from the instrument panel. Refer to; Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Top Cover Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Top Cover Demister Ducts Remove/Install 2. Remove the screws (two - left side, three - right side) that secure the demister ducts to the instrument panel top cover. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 4. Remove the demister ducts and the tee from the instrument panel top cover. 5. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. 7. Remove the demister ducts and the tee from the instrument panel top cover. 8. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top. 9. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Heater-A/C Housing Plenum Adapter 1. Remove the heater-A/C housing from the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service Precautions > Page 5172 Heater-A/C Housing Plenum Adapter Remove/Install 2. Slide the heater-A/C housing plenum adapter all the way to one side of the plenum opening. 3. Pull downwards sharply and firmly on the opposite side of the plenum adapter to disengage the snap feature from the plenum opening. 4. Remove the plenum adapter from the plenum panel. 5. When reinstalling the heater-A/C housing plenum adapter to the plenum panel opening, be certain that the snap features on each side of the adapter are fully engaged with the sides of the plenum panel opening. This must be a water tight connection to prevent leaks. 6. Reverse the remaining removal procedures to complete the installation. Rear Overhead A/C Outlet Bezel The rear overhead A/C outlet bezel is used only on models with the optional rear overhead A/C unit. The outlet barrels located in the bezel are only serviced as a unit with the rear overhead A/C outlet bezel. Rear Overhead A/C Outlet Bezel Remove/Install 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry between both ends of the rear overhead A/C outlet bezel and the headliner to release the two snap clip retainers that secure the bezel to the rear overhead A/C unit housing. 2. Remove the rear overhead A/C outlet bezel from the headliner mounting hole. 3. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 5.6 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5176 Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5177 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient air temperature is monitored by the Compass Mini-Trip Computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a 5 volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Compass Mini-Trip Computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5178 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC,, (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilohms. At 55 °C (131 °F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5179 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Blower Motor: > 24-06-00 > Aug > 00 > A/C Rear Fan Buzzing/Clicking Sound Auxiliary Blower Motor: Customer Interest A/C - Rear Fan Buzzing/Clicking Sound NUMBER: 24-06-00 GROUP: Heating & A/C DATE: August 25, 2000 SUBJECT: Rear A/C Blower Motor Fan Buzzing/Clicking Sound OVERVIEW: This bulletin involves repositioning the rear A/C assembly foam seal. MODELS: 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR A/C (SALES CODE HBA). SYMPTOM/CONDITION: The rear A/C blower motor fan contacts a thin plastic rib inside the rear overhead A/C unit when ambient temperatures exceeds 38°C. (100° F.) resulting in a buzzing/clicking sound. DIAGNOSIS/REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear A/C outlet bezel by gently separating the bezel from the headliner. 2. Gently, pull the headliner down. 3. Inspect the rear A/C assembly foam seal that seals the bottom of the A/C assembly to the headliner. Carefully, unfold any section of the foam seal that may be folded over and re-secure the foam seal in its proper place. If the foam will not release from itself, the folded over portion of foam must be cut out and removed. If the foam shows no signs of deformation, further diagnosis is required. NOTE: IT IS IMPORTANT TO ENSURE THAT ONLY ONE LAYER OF FOAM EXISTS BETWEEN THE BOTTOM OF THE A/C ASSEMBLY AND THE HEADLINER. THE BUZZING/CLICKING SOUND CAN OCCUR WHEN MORE THAN ONE LAYER OF FOAM IS PLACED BETWEEN THE BOTTOM OF THE A/C ASSEMBLY AND THE HEADLINER. 4. Push the headliner back into place and re-install the rear A/C outlet bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: XX - Service Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Blower Motor: > 24-06-00 > Aug > 00 > A/C - Rear Fan Buzzing/Clicking Sound Auxiliary Blower Motor: All Technical Service Bulletins A/C - Rear Fan Buzzing/Clicking Sound NUMBER: 24-06-00 GROUP: Heating & A/C DATE: August 25, 2000 SUBJECT: Rear A/C Blower Motor Fan Buzzing/Clicking Sound OVERVIEW: This bulletin involves repositioning the rear A/C assembly foam seal. MODELS: 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR A/C (SALES CODE HBA). SYMPTOM/CONDITION: The rear A/C blower motor fan contacts a thin plastic rib inside the rear overhead A/C unit when ambient temperatures exceeds 38°C. (100° F.) resulting in a buzzing/clicking sound. DIAGNOSIS/REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the rear A/C outlet bezel by gently separating the bezel from the headliner. 2. Gently, pull the headliner down. 3. Inspect the rear A/C assembly foam seal that seals the bottom of the A/C assembly to the headliner. Carefully, unfold any section of the foam seal that may be folded over and re-secure the foam seal in its proper place. If the foam will not release from itself, the folded over portion of foam must be cut out and removed. If the foam shows no signs of deformation, further diagnosis is required. NOTE: IT IS IMPORTANT TO ENSURE THAT ONLY ONE LAYER OF FOAM EXISTS BETWEEN THE BOTTOM OF THE A/C ASSEMBLY AND THE HEADLINER. THE BUZZING/CLICKING SOUND CAN OCCUR WHEN MORE THAN ONE LAYER OF FOAM IS PLACED BETWEEN THE BOTTOM OF THE A/C ASSEMBLY AND THE HEADLINER. 4. Push the headliner back into place and re-install the rear A/C outlet bezel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: XX - Service Adjustment Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5197 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5198 Blower Motor Relay: Diagrams Power Distribution Center Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5199 Blower Motor Relay: Description and Operation BLOWER MOTOR RELAY The blower motor relay (also referred to as Voltage Reduction Relay or VRR) is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The VRR is used to reduce blower speeds in Heat mode. In non-A/C modes, the relay is de-energized and switches the current flow through an added resistance in the resistor block. When an A/C mode is selected, the relay is energized and the normally open contact is used to bypass the added resistor. The fuse is located in the small relay fuse block that is attached to the Junction Block. The relay is energized by grounding the coil low side with the HVAC switch in any A/C mode. Blower Motor Relay (VRR) Location The blower motor relay is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Refer to the PDC label for blower motor relay identification and location. The blower motor relay (VRR) cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5200 Blower Motor Relay: Testing and Inspection RELAY TEST Blower Motor Relay Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Remove the blower motor relay 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 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 directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5201 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the ON position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. ADDITIONAL RELAY CIRCUIT TESTING - The relay common feed terminal cavity 30 is connected to the low side of the blower motor. When the blower switch is Off and the ignition is On, there should be battery voltage present on this circuit. When the ignition switch is On, the voltage at that point should vary based on blower switch position. - The normally closed contact cavity 87A is connected to the resistor block cavity 3. Check this circuit by turning the blower switch to High and cycling between Heat and A/C modes. The voltage in the Heat mode should be approximately 2 volts. The blower switch must be in High blower speed position during this check. - The normally open contact on cavity 87 is tied to both the resistor block cavity 6 and the HVAC blower switch cavity 6. Check for continuity on this circuit. - The coil B+ contact cavity 86 is connected to an ignition run start feed. Battery voltage should be present on this circuit when the ignition switch is in the Run position. - The coil ground (-) cavity 85 is connected to the HVAC switch cavity 2 as well as the JTEC and A/C high pressure switch. Battery voltage should be present on this circuit when the ignition switch is in the Run position and a Heat mode is selected on the control head. When an A/C mode is selected, the voltage at this point should be less than 1 volt. - If the blower motor does not operate, or only operates in some modes, check for a faulty connection at the VRR, or defective blower motor relay (VRR). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5202 Blower Motor Relay: Service and Repair REMOVAL Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box as described in Instrument Panel. Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Using a short or 90 degree screwdriver, remove the screw that secures the blower motor relay (VRR) to the steel clip in the instrument panel plastic flange. 4. Maneuver the VRR into the glove box opening far enough for access, and disengage the wiring harness from the relay. 5. Remove the relay through the glove box opening. INSTALLATION 1. Position the relay into the instrument panel inside the glove box opening. 2. Align the VRR with the connector and engage the wiring harness to the relay. 3. Align the relay with the steel clip in the instrument panel, and insert and tighten the single screw to 2.2 Nm (20 in. lbs.). 4. Roll up the glove box Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service Precautions Blower Motor Resistor: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service Precautions > Page 5206 Blower Motor Resistor: Description and Operation FRONT Blower Motor Resistor - Factory Installation During vehicle assembly, the blower motor resistor is mounted to the dash plenum panel inside the passenger compartment prior to instrument panel roll-up. However, a resistor mounting plate has been designed so that the resistor can be removed through an access hole in the cowl plenum panel just below the windshield. It can be accessed by removing the cowl plenum cover/grille panel. The resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground through the high speed blower motor relay. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. REAR The blower motor resistor for the optional rear overhead A/C unit is located within the unit housing. The resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service Precautions > Page 5207 Blower Motor Resistor: Testing and Inspection Both the front blower motor resistor and the optional rear overhead A/C unit blower motor resistor can be diagnosed using the procedure that follows. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the blower motor resistor. 3. Check for continuity between each of the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front Blower Motor Resistor: Service and Repair Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cowl plenum cover/grille panel from the cowl top. Refer to: "Vacuum Reservoir HVAC : Service and Repair" See: Vacuum Reservoir HVAC/Service and Repair Blower Motor Resistor Remove/Install 3. Reach through the cowl plenum access hole to remove the two hex screws that secure the front blower motor resistor to the cowl plenum panel. 4. Pull the front blower motor resistor and its wire harness out of the plenum panel and through the cowl plenum access hole far enough to access the wire harness connector. 5. Unplug the front blower motor resistor from the wire harness connector. 6. Remove the front blower motor resistor from the cowl plenum. INSTALLATION 1. Plug the front blower motor resistor into the wire harness connector. 2. Install the front blower motor resistor to the cowl plenum panel by feeding the resistor and wire harness back through the cowl plenum access hole. 3. Install and tighten the two screws that secure the front blower motor resistor to the cowl plenum panel. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 4. Reinstall the cowl plenum cover/grille panel to the cowl top. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 5210 Blower Motor Resistor: Service and Repair Rear The rear blower motor resistor is used only on models with the optional rear overhead A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Drain Hose Remove/Install 3. Disconnect the B-pillar drain hoses from the wye fittings on each side of the rear overhead A/C unit. 4. Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit. Rear Overhead A/C Unit Lower Housing Cover Remove/Install 5. Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit. 6. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 5211 Rear Blower Motor Resistor Remove/Install 7. Disengage the rear blower motor resistor wire harness connector retainer from the mounting hole in the right rear corner of the rear overhead A/C unit upper housing cover. 8. Unplug the rear blower motor resistor wire harness connector. 9. Remove the screw that secures the rear blower motor resistor bracket to the rear overhead A/C unit upper housing cover. 10. Remove the rear blower motor resistor and bracket as a unit from the rear overhead A/C unit. INSTALLATION 1. Position the rear blower motor resistor and bracket in the right rear corner of the rear overhead A/C unit upper housing cover and secure it with the mounting screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 2. Plug in the rear blower motor resistor wire harness connector. 3. Engage the rear blower motor resistor wire harness connector retainer to the mounting hole in the right rear corner of the rear overhead A/C unit upper housing cover. 4. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while positioning the cover to the unit. 5. Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged. 6. Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 7. Connect the B-pillar drain hoses to the wye fittings on each side of the rear overhead A/C unit. 8. Reinstall the headliner to the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner 9. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation FRONT The heater-A/C blower mot9r is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. REAR The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an OFF position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5215 Blower Motor Switch: Testing and Inspection FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to 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 heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. REAR 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch 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 rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to 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 rear blower motor switch as you move the blower motor switch knob to each of the three 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 rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 5216 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications at 12 Volts and +/- 0.5 V at 70 deg F Clutch Draw 2.0 - 3.9 A Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 5225 Compressor Clutch: Mechanical Specifications Clutch Air Gap ..................................................................................................................................... ............................. 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5226 A/C Compressor Clutch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5227 Compressor Clutch: Description and Operation Compressor Clutch - Typical The compressor clutch assembly consists of a stationary electromagnetic coil, a hub bearing and pulley assembly, and a clutch plate. The electromagnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is mounted to the compressor shaft and secured with a nut. These components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch into contact with the pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. The compressor clutch and coil are the only serviced parts on the compressor. The compressor clutch engagement is controlled by several components: the heater-A/C mode control switch, the electronic cycling clutch switch, the low pressure cut-off switch, the high pressure cut-off switch, the compressor clutch relay, and the Powertrain Control Module (PCM). The PCM may delay compressor clutch engagement for up to 30 seconds. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5228 Compressor Clutch: Service and Repair The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the serpentine drive belt. Refer to: "Drive Belts, Mounts, Brackets and Accessories : Drive Belt : Service and Repair" See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair 3. Unplug the compressor clutch coil wire harness connector. Clutch Nut Remove 4. Insert the two pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut. 5. Remove the clutch plate and the clutch shims. External Snap Ring Remove 6. Remove the external front housing snap ring with snap ring pliers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5229 Shaft Protector And Puller 7. Install the lip of the rotor puller (Special Tool C-6141-1 in Kit 6460) into the snap ring groove exposed in Step 6, and install the shaft protector (Special Tool C-6141-2 in Kit 6460). Install Puller Plate 8. Install the puller through-bolts (Special Tool C-6461) through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5230 Clutch Coil Lead Wire Harness 9. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. Clutch Field Coil Snap Ring Remove 10. Remove the snap ring from the compressor hub and remove the clutch field coil. Slide the clutch field coil off of the compressor hub. INSPECTION Examine the friction surfaces of the clutch pulley and the front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the compressor for oil. Remove the felt from the front cover. If the felt is saturated with oil, the shaft seal is leaking and the compressor must be replaced. Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required. INSTALLATION 1. Install the clutch field coil and snap ring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5231 2. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw. 3. Align the rotor assembly squarely on the front compressor housing hub Rotor Installer Set 4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460). Rotor Install 5. Place the driver tool assembly into the bearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor bearing inner race. 6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub, Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the rotor. 7. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor. 8. Install the original clutch shims on the compressor shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5232 Clutch Plate Install 9. Install the clutch plate. Use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the clutch plate. 10. Replace the compressor shaft hex nut. Tighten the nut to 14.4 Nm (10.5 ft. lbs.). Check Clutch Air Gap 11. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.41 to 0.79 mm (0.016 to 0.031 inch). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation. NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 mm (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch. 12. Reverse the remaining removal procedures to complete the installation. CLUTCH BREAK-IN After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the heater-A/C control to the recirculation mode (Max-A/C), the blower motor switch to the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The battery must be fully-charged before performing the following tests. 1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil. 2. With the heater-A/C mode control switch in any A/C mode, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle. 3. The compressor clutch coil voltage should read within two volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within two volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRB scan tool and the proper Diagnostic Procedures for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: Fuses in the junction block and the Power Distribution Center (PDC) - Heater-A/C mode control switch - Compressor clutch relay - Electronic clutch cycling switch - High pressure cut-off switch - Low pressure cut-off switch - Powertrain Control Module (PCM). 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21 °C (70 °F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the coil is open and should be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5239 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5240 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5241 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the electronic cycling clutch switch, the low pressure cut-off 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. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5242 Compressor Clutch Relay: Testing and Inspection RELAY TEST Compressor Clutch Relay 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 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 fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5243 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations Condenser HVAC: Locations The condenser is located in the air flow in front of the engine cooling radiator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations > Page 5247 Condenser HVAC: Description and Operation The condenser is located in the air flow in front of the engine cooling radiator. The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations > Page 5248 Condenser HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair Condenser Line Fittings 3. Disconnect the refrigerant line fitting that secures the discharge line to the condenser inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the refrigerant line fitting that secures the liquid line to the condenser outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 6. On models equipped with a V-8 engine, remove the radiator from the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Locations > Page 5249 Condenser Remove/Install - Typical 7. Remove the two screws that secure the condenser to the outside of the upper radiator cross-member. 8. Tilt the top of the radiator and fan shroud module towards the engine, using care not to damage the radiator fins on the engine cooling fan. 9. With the radiator and fan shroud module tilted, carefully lift the condenser upwards until the lower condenser mounts are clear of the isolators in the lower crossmember. 10. Remove the condenser from the vehicle. INSTALLATION 1. With the radiator and fan shroud module tilted towards the engine, carefully position the lower condenser mounts in the lower crossmember isolators. 2. Reinstall the two screws that secure the condenser to the outside of the upper radiator cross-member and tighten to 10.7 Nm (95 in. lbs.). 3. On models equipped with a V-8 engine, reinstall the radiator to the engine compartment. 4. Reinstall the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 5. Remove the plugs or tape from the refrigerant line fittings on the liquid line and the condenser outlet. Connect the liquid line to the condenser outlet. Tighten the fitting to 25.99 ± 3.39 Nm (230 ± 30 in. lbs.). 6. Remove the plugs or tape from the refrigerant line fittings on the discharge line and the condenser inlet. Connect the discharge line to the condenser inlet. Tighten the fitting to 25.99 ± 3.39 Nm (230 ± 30 in. lbs.). 7. Check that all of the condenser and radiator air seals are in their proper locations. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 10. Charge the refrigerant system. NOTE: If the condenser is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5258 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5259 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5260 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5261 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5262 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5263 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5264 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5265 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5266 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode Unbalanced Vent Air Flow > Page 5267 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. Press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5273 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5274 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5275 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5276 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5277 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5278 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5279 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5280 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5281 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 5282 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. Press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5283 Control Assembly: Specifications Heater A/C-Control Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5284 Control Assembly: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5285 Control Assembly: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application A/C Control .......................................................................................................................................... .......................................................................... 74 Heater Control ..................................................... ......................................................................................................................................................... 158 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Heater-A/C Control Test Control Assembly: Testing and Inspection Heater-A/C Control Test Satisfactory heater and air conditioner performance depends upon proper operation and adjustment of all operating controls and refrigeration system components. These inspections, tests, and adjustments should be used to locate the cause of a malfunction. Operation must be tested as described in the following sequence: 1. Move the temperature control knob quickly to the full hot and the full cold positions. There should be a distinct sound of the blend-air door hitting its stops within the heater-A/C housing at the end of knob travel in each direction, with no spring-back of the knob. If not OK, inspect the condition, routing, installation and adjustment of the temperature control cable. 2. Inspect and adjust the serpentine drive belt. 3. Start the engine and hold the idle speed at 1300 rpm. 4. On vehicles with air conditioning, turn the temperature control knob to the extreme counterclockwise (Cool) position, and set the mode control switch knob in the Bi-Level (A/C) position. The outside (recirculation) air door should be open to outside air. If not OK, see Vacuum System. 5. Open the vehicle windows. Test the blower motor operation in all speeds. If not OK, see Blower Motor. Leave the blower motor switch knob in the highest speed position. 6. On vehicles with air conditioning, the compressor should be running and the air conditioning system in operation unless the ambient air temperature is below about -1 °C (30 °F). If not OK, see A/C Performance. 7. Check the mode control switch operation. The heater and air conditioner systems should respond as described in the owner's manual in the vehicle glove box to each mode selected. Reduce the engine speed to normal idle. The vacuum will be high at low idle and the vacuum actuators should respond quickly. If not OK, see Vacuum System. 8. If the vacuum tests, and the electrical component and circuit tests reveal no problems, disassemble the heater-A/C housing to inspect for mechanical misalignment or binding of the mode doors. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Heater-A/C Control Test > Page 5288 Control Assembly: Testing and Inspection Heater-A/C Vacuum Controls Test 1. Connect the test set vacuum probe to the heater-A/C vacuum supply (black) tube in the engine compartment. Position the test set gauge so that it can be viewed from the passenger compartment. 2. Place the heater-A/C mode control switch knob in each mode position, one position at a time, and pause after each selection. The test set gauge should return to the 27 kPa (8 in. Hg.) setting shortly after each selection is made. If not OK, a component or vacuum line in the vacuum circuit of the selected mode has a leak. CAUTION: Do not use lubricant on the switch ports or in the holes in the plug, as lubricant will ruin the vacuum valve in the switch. A drop of clean water in the connector plug holes will help the connector slide onto the switch ports. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Page 5289 Control Assembly: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Refer to: Instrument Panel, Gauges and Warning Indicators, Instrument Cluster/Carrier, Service and Repair, Instrument Cluster Service Procedures, Instrument Cluster Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement Heater-A/C Control Remove/Install 3. Remove the four screws that secure the heater-A/C control to the instrument panel. 4. Pull the heater-A/C control assembly away from the instrument panel far enough to access the connections on the back of the control. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Page 5290 Heater-A/C Control Connection 5. Unplug the wire harness connector from the back of the heater-A/C control. 6. Disconnect the wire harness retainer from the side of the heater-A/C control assembly. 7. Remove the two stamped nuts that secure the vacuum harness connector and unplug the connector from the back of the heater-A/C control. 8. Release the temperature control cable housing flag retainer latch in the receptacle on the back of the heater-A/C control and disengage the flag retainer from the receptacle. 9. Rotate the heater-A/C control assembly to align the cable core with the slot on the end of the temperature control lever and disengage the cable end from the lever. 10. Remove the heater-A/C control from the instrument panel. INSTALLATION 1. Connect the temperature control cable core end to the temperature control lever on the back of the heater-A/C control. 2. Connect the temperature control cable housing flag retainer to the receptacle on the back of the heater-A/C control. 3. Plug in the vacuum harness connector and install the two stamped nuts to secure the connector to the back of the heater-A/C control. 4. Plug the wire harness connector into the back of the heater-A/C control. 5. Reinstall the wire harness retainer to the side of the heater-A/C control. 6. Position the heater-A/C control in the instrument panel and secure it with four screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Reinstall the cluster bezel to the instrument panel. Refer to: Instrument Panel, Gauges and Warning Indicators, Instrument Cluster/Carrier, Service and Repair, Instrument Cluster Service Procedures, Instrument Cluster Bezel Replacement, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Procedures/Instrument Cluster Bezel Replacement 8. Connect the battery negative cable. 9. Adjust the temperature control cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Spring-lock type refrigerant line couplers are used to connect many of the refrigerant lines and other components to the refrigerant system. These couplers require a special tool for disengaging the two coupler halves. Spring-Lock Coupler - Typical The spring-lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting. When the two coupler halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Two O-rings on the male half of the fitting are used to seal the connection. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. Secondary clips are installed over the two connected coupler halves at the factory for added blowoff protection. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Page 5294 Coupler HVAC: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 2. Remove the secondary clip from the spring-lock coupler. Refrigerant Line Spring-Lock Coupler Disconnect 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193) over the spring-lock coupler cage. 4. Close the two halves of the A/C line disconnect tool around the spring-lock coupler. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring. Once the garter spring is expanded and while still pushing the disconnect tool into the open side of the coupler cage, pull on the refrigerant line attached to the female half of the coupler fitting until the flange on the female fitting is separated from the garter spring and cage on the male fitting within the disconnect tool. NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 6. Open and remove the A/C line disconnect tool from the disconnected spring-lock coupler. 7. Complete the separation of the two halves of the coupler fitting. INSTALLATION 1. Check to ensure that the garter spring is located within the cage of the male coupler fitting, and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupler fitting. 3. Install new O-rings on the male half of the coupler fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak intermittently during vehicle operation. 4. Lubricate the male fitting and O-rings, and the inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female half of the coupler fitting over the male half of the fitting. 6. Push together firmly on the two halves of the coupler fitting until the garter spring in the cage on the male half of the fitting snaps over the flanged end on the female half of the fitting. 7. Ensure that the spring-lock coupler is fully engaged by trying to separate the two coupler halves. This is done by pulling the refrigerant lines on either side of the coupler away from each other. 8. Reinstall the secondary clip over the spring-lock coupler cage. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5303 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5304 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5305 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5306 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5307 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5308 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5309 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5310 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5311 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5312 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5313 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5314 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5320 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5321 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5322 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5323 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5324 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5325 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5326 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5327 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5328 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5329 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5330 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5331 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5332 Evaporator Core: Specifications Evaporator Coil to Rear Overhead A/C Unit Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5333 Evaporator Core: Locations The Front evaporator coil is located in the heater-A/C housing, under the instrument panel. The rear evaporator coil is located in the rear overhead A/C unit housing, above the headliner. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5334 Evaporator Core: Description and Operation FRONT The evaporator coil is located in the heater-A/C housing, under the instrument panel. The evaporator coil is positioned in the heater-A/C housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the evaporator. The evaporator coil cannot be repaired and, if faulty or damaged, it must be replaced. REAR The rear evaporator coil is located in the rear overhead A/C unit housing, above the headliner. The evaporator coil is positioned in the overhead A/C unit housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes. Refrigerant enters the evaporator from the rear expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the evaporator. The rear evaporator coil cannot be repaired and, if faulty or damaged, the rear evaporator coil must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator Evaporator Core: Service and Repair Front A/C Evaporator WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions - FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Evaporator Coil Remove/Install 2. Lift the front evaporator coil out of the heater-A/C housing. INSTALLATION 1. Insert the front evaporator coil into the bottom of the heater-A/C housing. 2. Reassemble and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation NOTE: If the front evaporator coil is replaced, add 60 ml (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 5337 Evaporator Core: Service and Repair Rear Evaporator WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions - FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The rear evaporator coil is used only on models with the optional rear overhead A/C unit. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install 4. From the passenger compartment, remove the nuts that secure the block fittings at the top of the B-pillar refrigerant lines to the studs on the rear overhead A/C unit, and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 5338 Rear Overhead A/C Drain Hose Remove/Install 5. Disconnect the B-pillar drain hoses from the wye fittings on each side of the rear overhead A/C unit. 6. Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit. Rear Overhead A/C Unit Lower Housing Cover Remove/Install 7. Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit. 8. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 5339 Rear A/C Tube Retaining Strap Remove/Install 9. Remove the screw that secures the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover. Rear Evaporator Coil Remove/Install 10. Remove the two screws that secure the rear evaporator coil to the rear overhead A/C unit upper housing cover. 11. Remove the rear evaporator coil from the rear overhead A/C unit. INSTALLATION 1. Position the rear evaporator coil to the rear overhead A/C unit and secure with two mounting screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Install the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover and secure with a screw. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 3. Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while positioning the cover to the unit. 4. Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged. 5. Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 6. Connect the B-pillar drain hoses to the wye fittings on each side of the rear overhead A/C unit. 7. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the two studs on the rear overhead A/C unit and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 8. Reinstall the headliner in the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 5340 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge NOTE: If the rear evaporator coil and expansion valve unit is replaced, add 30 ml (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation ELECTRONIC CYCLING CLUTCH SWITCH The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9 °C (37.2 °F), and will close again when the refrigerant temperature reaches about 4.3 °C (39.7 °F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5344 Evaporator Temperature Sensor / Switch: Testing and Inspection Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C9OA circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 to 30 °C (68 to 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle ON and OFF two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: If the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5345 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is filled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications Expansion Valve: Specifications Expansion Valve to Evaporator Tube Screws 11.4 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 5349 Expansion Valve: Locations The front "H" valve-type thermal expansion valve (TXV) is located at the dash panel between the liquid and suction lines, and the evaporator coil. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 5350 Expansion Valve: Service Precautions WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2) AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 5351 Expansion Valve: Description and Operation FRONT The front "H" valve-type thermal expansion valve (TXV) is located at the dash panel between the liquid and suction lines, and the evaporator coil. High-pressure, high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. A sensor in the expansion valve control head monitors the temperature and pressure of the refrigerant leaving the evaporator coil through the suction line, and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. REAR Vehicles equipped with the optional rear overhead A/C unit have an H-type thermal expansion valve (TXV) located underneath the passenger side of the vehicle floor panel, next to the sill. It performs the same function as the front expansion valve, to monitor refrigerant temperature and pressure at the control head and meter the refrigerant entering the evaporator to meet the vehicle cooling requirements. The rear expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the rear expansion valve unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 5352 Expansion Valve: Testing and Inspection These tests must be made at an ambient temperature of 21 - 29 °C (70 - 85 °F). Disconnect the wire connector at the low pressure cut off switch. Use a jumper wire to jumper terminals at the connector. FRONT A/C (Only) 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1000 rpm. Set the heater-A/C mode control switch knob to the recirculation mode (Max A/C) position, the temperature control knob to the full hot position, and the blower motor switch to the highest speed position. 2. Operate the air conditioning system for at least 5 minutes to stabilize the system, and to provide sufficient reheat to load the evaporator. The discharge pressure (high side) at the service port should reach 966 - 1656 kPa (140 - 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2), AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Apply liquid carbon dioxide (CO2) to the expansion valve control head (completely cover the head) for a minimum of thirty seconds. Observe the manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this reading is not obtained, the expansion valve is faulty and must be replaced. 4. Remove the liquid carbon dioxide (CO2) from the control head. Observe the manifold gauge set. The suction pressure (low side) must increase to a minimum of 262 kPa (38 psi), and then stabilize to a pressure of 172 - 240 kPa (25 - 35 psi). If these readings are not obtained, the expansion valve is faulty and must be replaced. 5. Set the engine idle speed at 1000 rpm and the blower motor switch to the highest speed position. The suction pressure (low side) should be 138 207 kPa (20 - 30 psi). If the discharge pressure (high side) is higher than 1656 kPa (240 psi), check for a restricted discharge line. Also check the engine cooling system for overheating, air trapped in the system, or a faulty fan drive. If the discharge pressure (high side) is less than 966 kPa (140 psi), check for a faulty compressor. FRONT AND REAR A/C 1. Attach a manifold gauge set. Close the vehicle doors and windows, start the engine, and hold the engine speed at 1000 rpm. Set the heater-A/C mode control switch knob to the recirculation mode (Max A/C) position, the temperature control knob to the full hot position, and both the front and rear blower motor switches to their highest speed positions. 2. Operate the air conditioning system for at least five minutes to stabilize the system, and to provide sufficient reheat to load the front and rear evaporators. The discharge pressure (high side) at the service port should reach 966 to 1656 kPa (140 to 240 psi). If this discharge pressure cannot be obtained, check the refrigerant system charge. WARNING: EXTREME CARE MUST BE USED WHEN HANDLING LIQUID CARBON DIOXIDE (CO2) AS SKIN INJURY CAN OCCUR. PROTECTIVE GLOVES SHOULD BE WORN. 3. Both the front and rear expansion valves should be checked for correct operation. Apply liquid carbon dioxide (CO2) to the front expansion valve control head (completely cover the head) for a minimum of thirty seconds. Observe the manifold gauge set. The suction pressure (low side) must drop to below 50 kPa (7.25 psi). If this reading is not obtained, the expansion valve is faulty and must be replaced. 4. Apply liquid carbon dioxide (CO2) to the front expansion valve control head (completely cover the head) for a minimum of thirty seconds. Remove the protective cover and apply liquid carbon dioxide (CO2) to the rear expansion valve control head. Grasp the suction line (large line) off the evaporator with a bare hand and hold it for at least two minutes. Use the same procedure with the front expansion valve. Grasp the suction line jumper below the expansion valve (before the rear suction line tee) with a bare hand and hold for at least two minutes. When testing the front expansion valve, place the rear blower motor switch in the OFF position. 5. With a correctly operating expansion valve, the suction line will feel warm with the closing of the valve (cold applied). Then the line will cool sharply within two minutes as the valve opens. If this temperature change does not occur, the expansion valve is faulty and must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front Expansion Valve: Service and Repair Front WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 3. Remove the rear liquid line from the engine compartment. 4. Remove the electronic cycling clutch switch from the outboard side of the expansion valve. Expansion Valve Remove/Install 5. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange. 6. Remove the expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. INSTALLATION 1. Remove the tape or plugs from the evaporator tubes and the evaporator tube mounting flange side of the expansion valve. Install the expansion valve to the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 Nm (100 in. lbs.). 2. Reinstall the electronic cycling clutch switch to the outboard side of the expansion valve. 3. Reinstall the rear liquid line to the engine compartment. 4. Connect the battery negative cable. 5. Evacuate the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 6. Charge the refrigerant system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front > Page 5355 Expansion Valve: Service and Repair Rear WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 3. Remove the engine air filter housing. 4. Remove the underbody line. Refer to: "Hose/Line HVAC : Service and Repair : Underbody Refrigerant Line Replacement" See: Hose/Line HVAC/Service and Repair. Remove the line from the vehicle and install plugs in, or tape oven all of the open refrigerant fittings. 5. Disassemble the bolt (M6) from the forward (longer) section of the underbody lines to the valve. Install plugs in, or tape over the open refrigerant fittings. 6. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) of the underbody lines. Install plugs in, or tape over the open refrigerant fittings. INSTALLATION 1. Remove the tape or plugs from expansion valve and the rearward (shorter) section of the underbody lines. Align the expansion valve ports with the block fitting on the rearward lines and assemble with the two bolts. 2. Remove the tape or plugs from the forward (longer) section of the underbody lines. Align the expansion valve ports and stud with the block fitting on the forward lines. Secure with the mounting bolt. 3. Install the underbody refrigerant lines. Refer to: "Hose/Line HVAC : Service and Repair : Underbody Refrigerant Line Replacement" See: Hose/Line HVAC/Service and Repair 4. Install the engine air filter housing. 5. Evacuate and charge the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 6. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heater Core: Locations The heater core is located in the heater-A/C housing, under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5359 Heater Core: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5360 Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5361 Heater Core: Service and Repair WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions - FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Remove the heater-A/C housing from the vehicle, and remove the housing cover. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Heater Core Remove/Install 2. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Reassemble and reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal and Installation Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 5365 High Pressure Safety Valve HVAC: Description and Operation A high pressure relief valve is located on the compressor cylinder head, which is at the rear of the compressor. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system components, caused by condenser air flow restriction or an overcharge of refrigerant. The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents refrigerant, it does not mean the valve is faulty. The high pressure relief valve is a factory-calibrated unit. The valve cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the compressor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with peanut- block style fittings. A stat-0 seal type flat steel gasket with a captured compressible O-ring, and spring lock coupler, is used to mate plumbing lines with A/C components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5371 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Front Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery Liquid Line Remove/Install 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. See Refrigerant Line Coupler for the procedures. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5372 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Rear Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5373 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Suction Line Jumper Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the rear liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suetion line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Suction and Discharge Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5374 Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5375 Hose/Line HVAC: Service and Repair B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt - suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5376 B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the lower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. 'Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Reinstall the lower B-pillar trim panel, upper trim panel, and seat belt bolt adjuster. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. See Refrigerant Line Coupler for the procedures. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 11. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5377 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Front Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5378 Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery Liquid Line Remove/Install 3. Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the front liquid line from the engine compartment. INSTALLATION 1. Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. See Refrigerant Line Coupler for the procedures. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5379 Rear Any kinks or sharp bends in the refrigerant plumbing Will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Remove the engine air filter housing. 4. Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. 5. Remove the screw that secures the rear liquid line block fitting to the outlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Disconnect the suction line from the suction jumper. 7. If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Disengage the clip that secures the rear liquid line to the inner fender shield. 9. Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve. Install plugs in, or tape over all of the opened refrigerant line fittings. 10. Remove the rear liquid line from the engine compartment. 11. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Install the suction line jumper into the rear liquid line block fitting. 2. Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 Nm (200 in. lbs.). 3. Install the rear liquid line in the clip on the inner fender shield. 4. If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. 5. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). Connect the suction line from the suction discharge assembly to the suction jumper tube. 6. Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting. Tighten the mounting screw to 6.8 Nm (60 in. lbs.). 7. Reinstall the engine air filter housing. 8. Connect the battery negative cable. 9. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 10. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Suction Line Jumper Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the low pressure cut-off switch from the fitting on the suction line jumper. 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 4. Disconnect the refrigerant line coupler between the suction line and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5380 5. Remove the rear liquid line from the engine compartment. 6. Slide the plastic retainer that secures the suetion line jumper out of the saddle formation at the top of the rear liquid line block fitting. Secure block, preferably in a vise. Tap the plastic retainer out with a hammer and flat-bladed screwdriver. 7. Remove the suction line jumper from the rear liquid line block fitting. INSTALLATION 1. Using a new O-ring, install the suction line jumper into the saddle formation at the top of the rear liquid line block fitting. 2. Slide the plastic retainer that secures the suction line jumper into the rear liquid line block fitting. 3. Install the rear liquid line into the engine compartment. 4. Remove the tape or plugs from the refrigerant line fittings on the suction line and the suction line jumper. Install the suction line to the suction line jumper. 5. Install the low pressure cut-off switch to the fitting on the suction line jumper. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Suction and Discharge Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the refrigerant line support bracket near the compressor. Suction And Discharge Line Remove/Install 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5381 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 Nm (200 in. lbs.). 3. Install the nut that secures the refrigerant line support bracket near the compressor. 4. Plug in the wire harness connector to the high pressure cut-off switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge B-Pillar Refrigerant Line Replacement The B-pillar refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the B-pillar suction line and the B-pillar liquid line are available for separate service replacement. Each line may be removed independently from the vehicle for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Raise and support the vehicle. 4. From under the vehicle, disconnect the underbody liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Lower the vehicle. 6. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5382 7. From the passenger compartment, remove the fasteners that secure the block fittings at the top of the B-pillar refrigerant lines to the rear overhead A/C unit (nut from stud - liquid line) (nut and bolt - suction line), and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. B-Pillar Refrigerant Lines Remove/Install 8. Remove the two screws that secure the B-pillar refrigerant line clamps to the B-pillar. 9. Remove the two screws that secure the B-pillar refrigerant line clamp and seal unit to the floor panel at the base of the B-pillar. 10. Tilt the top of the B-pillar refrigerant line unit towards the front of the vehicle far enough so that the lower end of the unit can be lifted out through the hole in the floor panel. 11. Remove the B-pillar refrigerant line unit from the passenger compartment. NOTE: If either the liquid line or the suction line is removed from the B-pillar refrigerant line clamp and seal, the clamp and seal will be damaged. Replace the clamp and seal with a new unit. INSTALLATION 1. Position the B-pillar refrigerant line unit in the passenger compartment with the lower end of the lines inserted through the hole in the floor panel at the base of the B-pillar, and the top end of the lines oriented towards the front of the vehicle. 2. 'Tilt the top of the B-pillar refrigerant line unit up into position near the rear overhead A/C unit. 3. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 4. Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 5. Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw. Tighten the mounting screw to 2.2 Nm (20 in. lbs.). 6. Reinstall the headliner in the passenger compartment. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Reinstall the lower B-pillar trim panel, upper trim panel, and seat belt bolt adjuster. 7. Raise and support the vehicle. 8. From under the vehicle, remove the tape or plugs from the refrigerant line fittings at the underbody and B-pillar liquid lines, and from the underbody and B-pillar suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. See Refrigerant Line Coupler for the procedures. 9. Connect the battery negative cable. 10. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5383 11. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Refrigerant Hoses/Lines/Tubes Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 mm (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system Will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry All tools and equipment must be designed for R-134a refrigerant. Underbody Refrigerant Line Replacement The underbody refrigerant lines are used only on models with the optional rear overhead A/C unit. Both the underbody suction line and the underbody liquid line are available for separate service replacement, and may be removed from the vehicle independently for service. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5384 Underbody Refrigerant Line Remove/Install 3. From the engine compartment, disconnect the underbody liquid line refrigerant line coupler at the liquid line extension and the underbody suction line refrigerant line coupler at the suction line jumper. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Raise and support the vehicle. 5. From under the vehicle, disconnect the under-body liquid line refrigerant line coupler at the B-pillar liquid line and the underbody suction line refrigerant line coupler at the B-pillar suction line. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screws that secure the three underbody refrigerant line clamps to the underbody. 7. Remove the underbody refrigerant line unit from the vehicle. INSTALLATION 1. From under the vehicle, position the underbody refrigerant line unit to the underbody and secure the refrigerant line clamps with the mounting screws in three places. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). 2. Remove the tape or plugs from the refrigerant line fittings at the rear of the underbody liquid and suction lines and at the B-pillar liquid and suction lines. Connect the underbody refrigerant lines to the B-pillar refrigerant lines. 3. Lower the vehicle. 4. From the engine compartment, remove the tape or plugs from the refrigerant line fittings at the front of the underbody liquid and suction lines and at the liquid line extension and the suction line jumper. Connect the underbody refrigerant lines to the engine compartment refrigerant lines. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 7. Charge the refrigerant system. Refer to Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service Precautions Housing Assembly HVAC: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Front HVAC Housing Removal and Installation The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, Refer to: "Restraint Systems : Air Bag Systems" See: Restraint Systems/Air Bag Systems/Service Precautions - FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 3. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 4. Remove the front expansion valve from the evaporator tube mounting flange. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Drain the engine cooling system. 6. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. Heater-A/C Housing Remove/Install 7. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. 8. Disengage the front floor panel transmission tunnel duct from the adapter on the heater-A/C housing. 9. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. INSTALLATION. 1. Position the heater-A/C housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5390 inserted into their correct mounting holes. 2. Install the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. Tighten the nut to 11 Nm (95 in. lbs.). 3. Engage the front floor panel transmission tunnel duct with the adapter on the heater-A/C housing. 4. Install and tighten the four nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.). 5. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. 6. Reinstall the front expansion valve to the evaporator tube mounting flange. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge 9. Reinstall the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly 10. Connect the battery negative cable. 11. Start the engine and check for proper operation of the heating and air conditioning systems. Rear HVAC Housing Removal and Installation WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Recovery, See: Service and Repair/Refrigerant System Recovery 3. Remove the headliner from the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner Rear Overhead A/C Unit Refrigerant Line Remove/Install 4. From the passenger compartment, remove the nut from the bolt, (suction line) and nut from stud, (liquid line) that secure the block fittings at the Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5391 top of the B-pillar refrigerant lines on the rear overhead A/C unit, and disengage the fittings. Install plugs in, or tape over all of the opened refrigerant line fittings. Rear Overhead A/C Drain Hose Remove/Install 5. Disconnect the B-pillar drain hoses from the wye fittings on each side of the rear overhead A/C unit. 6. Unplug the rear overhead A/C unit wire harness connector located at the left side of the unit. Rear Overhead A/C Unit Remove/Install 7. Loosen but do not remove the two screws that secure the mounting bracket on the left end of the rear overhead A/C unit to the left roof rail. 8. Support the right end of the rear overhead A/C unit while removing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail. 9. Slide the rear overhead A/C unit towards the right side of the vehicle far enough to disengage the slotted holes on the left end of the mounting bracket from the loosened screws in the left roof rail. 10. Remove the rear overhead A/C unit from the passenger compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5392 INSTALLATION 1. Engage the slotted holes in the left end of rear overhead A/C unit mounting bracket with the loosened screws in the left roof rail. 2. Support the right end of the rear overhead A/C unit while installing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail. Tighten all of the mounting screws to 11.9 Nm (105 in. lbs.). 3. Plug in the rear overhead A/C unit wire harness connector located at the left side of the unit. 4. Connect the B-pillar drain hoses to the wye fittings on each side of the rear overhead A/C unit. 5. Remove the tape or plugs from block fittings at the top of the B-pillar refrigerant line unit, and from the fittings on the rear overhead A/C unit. Install the B-pillar refrigerant line block fittings over the one stud on the rear overhead A/C unit. Install the bolt holding the suction line, and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 Nm (100 in. lbs.). 6. Reinstall the headliner in the passenger compartment of the vehicle. Refer to: "Body and Frame : Interior Trim : Headliner" See: Body and Frame/Interior Moulding / Trim/Headliner 7. Connect the battery negative cable. 8. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair/Refrigerant System Evacuate 9. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Service and Repair/Refrigerant System Charge NOTE: If the rear overhead A/C unit is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5393 Housing Assembly HVAC: Overhaul The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: - REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. DISASSEMBLY 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Removal and Replacement/Front HVAC Housing Removal and Installation 2. Remove the two screws that secure the heater- A/C housing cover to the top of the blower motor housing cover. 3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. 4. Unplug the vacuum harness connector from the panel-defrost door actuator. 5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing. Heater-A/C Housing Floor Outlet Screws 6. Remove the two screws that secure the heater- A/C housing cover to the lower housing near the floor outlet. 7. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing up. 8. Disengage the vacuum harness retainer from the hole near the left end of the heater-A/C housing cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5394 Blend-Air Door Lever Remove/Install 9. Remove the vacuum harness from the molded clips on the heater-A/C housing cover. 10. Remove the thirteen screws that secure the perimeter of the housing cover to the heater-A/C housing. 11. Remove the nut that secures the blend-air door lever to the blend-air door pivot shaft and remove the lever. 12. Gently pry off the push nut that secures the heater-A/C housing cover to the heater-A/C housing post. Panel-Defrost Door Lever Remove 13. Using a trim stick or another suitable wide flat-bladed tool, gently pry the panel-defrost door lever off of the panel-defrost door pivot shaft. 14. Pull up the perimeter edges of the heater-A/C housing cover far enough to separate the cover sealant from the heater-A/C housing. 15. Remove the housing cover from the heater- A/C housing. 16. If the vehicle is so equipped, remove the recirculation air door actuator from the blower motor housing cover. Refer to: "Air Door : Service and Repair" See: Air Door/Air Door Actuator / Motor/Service and Repair Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5395 Blower Motor Housing Cover Remove/Install 17. Remove the six screws that secure the blower motor housing cover to the heater-A/C housing. 18. Remove the blower motor housing cover from the heater-A/C housing. ASSEMBLY Blower Motor Housing Cover Sealent 1. Before installing the blower motor housing cover, be certain that the cover sealant is in place and in good condition. 2. Position the blower motor housing cover to the heater-A/C housing. 3. Install the six screws that secure the blower motor housing cover to the heater-A/C housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. If the vehicle is so equipped, reinstall the recirculation air door actuator. See Mode Door Vacuum Actuators for the procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5396 Heater-A/C Housing Cover Sealant 5. Before installing the heater-A/C housing cover, be certain that the cover sealant is in place and in good condition. 6. Position the heater-A/C housing cover on the heater-A/C housing. Be certain that the pivots for the floor-defrost, the panel-defrost, the blend-air, and the recirculation air (if the vehicle is so equipped) doors are properly positioned. 7. Reinstall the push nut that secures the heater- A/C housing cover to the heater-A/C housing post. 8. Install the thirteen screws that secure the perimeter of the housing cover to the heater-A/C housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 9. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 10. Install the blend-air door lever to the blend- air door pivot shaft and secure it to the shaft with the nut. 11. Install the vacuum harness retainer into the hole near the left end of the heater-A/C housing cover. 12. Route the vacuum harness through the molded clips on the heater-A/C housing cover. 13. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing down. 14. Install the two screws that secure the heater- A/C housing cover to the lower housing near the floor outlet. Tighten the screws to 2.2 Nm (20 in. lbs.). 15. Position the floor duct to the bottom of the heater-A/C housing and secure with four screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 16. Plug in the vacuum harness connector to the panel-defrost door actuator. 17. If the vehicle is so equipped, plug in the two vacuum harness connectors to the recirculation air door actuator. 18. Install the two screws that secure the heaterA/C housing cover to the top of the blower motor housing cover. Tighten the screws to 2.2 Nm (20 in. lbs.). 19. Reinstall the heater-A/C housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Front, Front HVAC Unit Removal and Installation, See: Removal and Replacement/Front HVAC Housing Removal and Installation Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications Filter-Drier Inlet Screw 13.5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5400 Receiver Dryer: Locations The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5401 Receiver Dryer: Description and Operation The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 5402 Receiver Dryer: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. Remove the filter-drier from the engine compartment. INSTALLATION 1. Position the filter-drier and its bracket to the front fender wheelhouse front extension as a unit and loosely secure it with the mounting screw. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 4. Tighten the filter-drier bracket mounting screw to 6.8 Nm (60 in. lbs.). 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 7. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Refrigerant Single Unit ......................................................................................................................................................... 0.793 kilograms (28 oz.) R134a Refrigerant Dual Unit ........................................................................................................................................................... 0.907 kilograms (32 oz.) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5407 Refrigerant: Fluid Type Specifications HydroFluoroCarbon (HFC), ....................................................................................................................................................... R-134a liquified freon gas Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5408 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5409 http://www.macsw.org/ Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Locations Refrigerant Filter: Locations The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Locations > Page 5413 Refrigerant Filter: Description and Operation The filter-drier is mounted on the right front wheelhouse front extension in the engine compartment, in the liquid line between the condenser outlet and the evaporator inlet. Refrigerant enters the filter-drier as a high-pressure, high-temperature liquid The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Locations > Page 5414 Refrigerant Filter: Service and Repair WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: "Service and Repair" See: Service and Repair Filter-Drier Remove/Install 3. Remove the screws that secure the front and rear liquid line block fittings to the filter-drier inlet and outlet. Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. 4. Remove the screw that secures the filter-drier mounting bracket to the front fender wheelhouse front extension. 5. Remove the filter-drier from the engine compartment. INSTALLATION 1. Position the filter-drier and its bracket to the front fender wheelhouse front extension as a unit and loosely secure it with the mounting screw. 2. Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 3. Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw. Tighten the mounting screw to 13.5 Nm (120 in. lbs.). 4. Tighten the filter-drier bracket mounting screw to 6.8 Nm (60 in. lbs.). 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. Refer to: "Service and Repair" See: Service and Repair 7. Charge the refrigerant system. NOTE: If the filter-drier is replaced, add 30 ml (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System Front .................................................................................................................................................... ...................................................... 180 ml (6.1 oz.) Front & Rear ....................................................... .......................................................................................................................................... 240 ml (8 oz.) Filter-Drier ............................................................................................................................................ ............................................................. 30 ml (1 oz.) Condenser ........................................................................................................................................... ................................................................ 30 ml (1 oz.) Evaporator Front .................................................................................................................................................... ........................................................... 60 ml (2 oz.) Rear .................................................................... ............................................................................................................................................ 30 ml (1 oz.) Compressor ......................................................................................................................................... ...................................................................... See Note Note: When replacing the A/C compressor, drain and measure the amount of oil from the old compressor. Add the equivalent amount of fresh oil to the new compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5419 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type SP-20 PAG Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5420 Refrigerant Oil: Service and Repair When an air conditioning system is assembled at the factory, all components except the compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The evaporator, filter-drier, condenser, and compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the air conditioning system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 ml (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when a filter-drier, evaporator coil, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations The high pressure cut-off switch is located on the discharge line near the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5425 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch, the low pressure cut-off switch, and the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 - 3375 kPa (450 - 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 - 2275 kPa (270 - 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5426 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the dual function high pressure switch, or the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure switch wire harness connector from the switch on the refrigerant system fitting. 3. On the dual function high pressure switch, check for continuity between terminals C and D. On the two terminal switch, check for continuity between both terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5427 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations The low pressure cut-off switch is located on the suction line jumper tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5431 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The low pressure cut-off switch is located on the suction line jumper tube. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The fitting is equipped with an O-ring to seal the switch connection. The low pressure cut-off switch is connected in series electrically with the high pressure cut-off switch, the heater-A/C controls, the Electronic Cycling Clutch Switch (ECCS), between ground, 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 refrigerant system pressure, ensuring a sufficient amount of refrigerant throughout the system. The low pressure cut-off switch contacts will open when the suction pressure is about 48 to 90 kPa (7 to 13 psi) or lower. The switch contacts will close when the suction pressure rises to about 103 to 193 kPa (15 to 28 psi) or above. Lower ambient temperatures, below about -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cut-off switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5432 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1 °C (30 °F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 48 to 193 kPa (15 to 28 psi) or above, and no continuity with a suction pressure reading of 90 kPa (13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5433 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Center Blower Motor Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5438 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5439 Blower Motor Relay: Diagrams Power Distribution Center Blower Motor Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5440 Blower Motor Relay: Description and Operation BLOWER MOTOR RELAY The blower motor relay (also referred to as Voltage Reduction Relay or VRR) is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. The VRR is used to reduce blower speeds in Heat mode. In non-A/C modes, the relay is de-energized and switches the current flow through an added resistance in the resistor block. When an A/C mode is selected, the relay is energized and the normally open contact is used to bypass the added resistor. The fuse is located in the small relay fuse block that is attached to the Junction Block. The relay is energized by grounding the coil low side with the HVAC switch in any A/C mode. Blower Motor Relay (VRR) Location The blower motor relay is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Refer to the PDC label for blower motor relay identification and location. The blower motor relay (VRR) cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5441 Blower Motor Relay: Testing and Inspection RELAY TEST Blower Motor Relay Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. Remove the blower motor relay 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 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 directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5442 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the ON position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. ADDITIONAL RELAY CIRCUIT TESTING - The relay common feed terminal cavity 30 is connected to the low side of the blower motor. When the blower switch is Off and the ignition is On, there should be battery voltage present on this circuit. When the ignition switch is On, the voltage at that point should vary based on blower switch position. - The normally closed contact cavity 87A is connected to the resistor block cavity 3. Check this circuit by turning the blower switch to High and cycling between Heat and A/C modes. The voltage in the Heat mode should be approximately 2 volts. The blower switch must be in High blower speed position during this check. - The normally open contact on cavity 87 is tied to both the resistor block cavity 6 and the HVAC blower switch cavity 6. Check for continuity on this circuit. - The coil B+ contact cavity 86 is connected to an ignition run start feed. Battery voltage should be present on this circuit when the ignition switch is in the Run position. - The coil ground (-) cavity 85 is connected to the HVAC switch cavity 2 as well as the JTEC and A/C high pressure switch. Battery voltage should be present on this circuit when the ignition switch is in the Run position and a Heat mode is selected on the control head. When an A/C mode is selected, the voltage at this point should be less than 1 volt. - If the blower motor does not operate, or only operates in some modes, check for a faulty connection at the VRR, or defective blower motor relay (VRR). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5443 Blower Motor Relay: Service and Repair REMOVAL Blower Motor Relay (VRR) Location The blower motor relay (Voltage Reduction Relay or VRR) is mounted with a single screw directly to the instrument panel's structural plastic inside the glove box opening, next to the left-side energy-absorbing bracket. 1. Disconnect and isolate the battery negative cable. 2. Roll down the glove box as described in Instrument Panel. Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Using a short or 90 degree screwdriver, remove the screw that secures the blower motor relay (VRR) to the steel clip in the instrument panel plastic flange. 4. Maneuver the VRR into the glove box opening far enough for access, and disengage the wiring harness from the relay. 5. Remove the relay through the glove box opening. INSTALLATION 1. Position the relay into the instrument panel inside the glove box opening. 2. Align the VRR with the connector and engage the wiring harness to the relay. 3. Align the relay with the steel clip in the instrument panel, and insert and tighten the single screw to 2.2 Nm (20 in. lbs.). 4. Roll up the glove box Refer to: "Instrument Panel, Gauges and Wiring indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center A/C Clutch Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5447 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5448 Compressor Clutch Relay: Diagrams Power Distribution Center A/C Compressor Clutch Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5449 Compressor Clutch Relay: Description and Operation COMPRESSOR CLUTCH RELAY The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the electronic cycling clutch switch, the low pressure cut-off 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. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5450 Compressor Clutch Relay: Testing and Inspection RELAY TEST Compressor Clutch Relay 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 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 fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5451 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Temperature Sensor Bracket to Radiator Yoke Screw 5.6 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5456 Ambient Temperature Sensor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5457 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient air temperature is monitored by the Compass Mini-Trip Computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a 5 volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Compass Mini-Trip Computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5458 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The thermometer function is supported by the ambient temperature sensor, a wiring circuit, and a portion of the compass mini-trip computer module. If any portion of the ambient temperature sensor circuit fails, the compass/thermometer display function will self-diagnose the circuit. An "SC,, (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 ° F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Compass Mini-Trip Computer. Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilohms. At 55 °C (131 °F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the faulty ambient temperature sensor. Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the roof wire harness overhead console connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the roof wire harness overhead console connector and a good ground. There should be no continuity. If OK, refer to Compass Mini-Trip Computer. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 5459 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the right side of the radiator yoke behind the grille. 3. Disconnect the wire harness connector from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. INSTALLATION 1. Position the ambient temperature sensor onto the radiator yoke. 2. Install and tighten the one screw that secures the ambient temperature sensor bracket to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.) . 3. Reconnect the wire harness connector to the ambient temperature sensor connector receptacle. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation FRONT The heater-A/C blower mot9r is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground through the high speed blower motor relay, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately. REAR The optional rear overhead A/C unit blower motor is controlled by a four position rotary-type blower motor switch, mounted by a snap fit in a hole in the headliner over the right front seat back. The switch allows the selection of one of three blower motor speeds and an OFF position. The blower motor switch directs the blower motor ground path through the blower motor resistor. The blower motor switch cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The blower motor switch has a replaceable incandescent-type illumination lamp bulb. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 5463 Blower Motor Switch: Testing and Inspection FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob to 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 heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. REAR 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the rear blower motor switch from the headliner. Check for continuity between the ground circuit cavity of the rear blower motor switch 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 rear blower motor switch wire harness connector unplugged, place the rear blower motor switch knob to 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 rear blower motor switch as you move the blower motor switch knob to each of the three 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 rear blower driver circuits between the rear blower motor switch wire harness connector and the blower motor resistor as required. If not OK, replace the faulty rear blower motor switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 5464 Blower Motor Switch: Service and Repair The rear blower motor switch is used only on models with the optional rear overhead air conditioning unit. REMOVAL 1. Disconnect and isolate the battery negative cable. Rear Blower Motor Switch Remove/Install 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry above the two indentations at the outer perimeter of the rear blower motor switch to release it from the headliner. 3. Pull the rear blower motor switch away from the headliner far enough to access and unplug the wire harness connector from the back of the switch. 4. Remove the rear blower motor switch from the headliner. INSTALLATION 1. Plug the wire harness connector into the back of the rear blower motor switch. 2. Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner. 3. Gently press the rear blower motor switch into the mounting hole in the headliner until it snaps into place. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation ELECTRONIC CYCLING CLUTCH SWITCH The Electronic Cycling Clutch Switch (ECCS) is mounted to the outboard side of the thermal expansion valve in the engine compartment. A thermistor probe within a capillary tube on the switch is inserted into a well on the side of the expansion valve filled with a thermally-conductive grease. This arrangement allows the ECCS to monitor the temperature of the expanded refrigerant entering the evaporator. The function of the ECCS is to prevent refrigerant temperatures from becoming so low that condensation freezes on the evaporator fins. This condition is referred to as evaporator icing. Evaporator icing reduces air conditioning system air flow and cooling performance. The ECCS is connected in series electrically with the heater-A/C mode control switch, the low pressure cut-off switch and the high pressure cut-off switch between ground and the Powertrain Control Module (PCM). The ECCS will open when it monitors a refrigerant temperature below about 2.9 °C (37.2 °F), and will close again when the refrigerant temperature reaches about 4.3 °C (39.7 °F). The opening and closing of the ECCS signals the PCM to cycle the compressor clutch on and off through the compressor clutch relay. The ECCS is a factory sealed and calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the ECCS must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5468 Evaporator Temperature Sensor / Switch: Testing and Inspection Use a volt/ohmmeter to test the electronic cycling clutch switch. Verify that the refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described before testing the electronic cycling clutch switch. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connectors at the electronic cycling clutch switch and the high pressure cut-off switch. Check for continuity between the C9OA circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the high pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Unplug the wire harness connector at the low pressure cut-off switch. Check for continuity between the C2 circuit cavities in the body half of the electronic cycling clutch switch wire harness connector and the low pressure cut-off switch wire harness connector. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Plug in the wire harness connectors at the low pressure cut-off and high pressure cut-off switches. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity in the body half of the electronic cycling clutch switch wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit to the junction block as required. 4. Plug in the wire harness connector at the electronic cycling clutch switch. With the ambient temperature from 20 to 30 °C (68 to 90 °F), start the engine and set the heater-A/C mode control switch in any A/C position. If the compressor clutch fails to engage, use a DRB III scan tool and the proper Diagnostic Procedures to check the Powertrain Control Module (PCM) and its inputs and outputs. If the compressor clutch engages, the clutch should cycle ON and OFF two to three times per minute. If the clutch fails to cycle at this rate in these ambient temperatures, replace the faulty electronic cycling clutch switch. NOTE: If the ambient temperature is above 32 °C (90 °F) the compressor clutch may stay engaged and not cycle due to the high heat load. This condition is normal. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 5469 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Electronic Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve. 3. Remove and discard the fastener that secures the electronic cycling clutch switch to the outboard side of the expansion valve. 4. Pull the electronic cycling clutch switch away from the side of the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed. NOTE: The capillary tube well in the expansion valve is filled with a special thermally-conductive grease. This grease should be removed from the old parts and reused on the new parts whenever the electronic cycling clutch switch or the expansion valve are replaced. INSTALLATION 1. Insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well on the outboard side of the expansion valve. 2. Install the electronic cycling clutch switch to the expansion valve and secure it with a new fastener. 3. Plug the wire harness connector into the electronic cycling clutch switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations The high pressure cut-off switch is located on the discharge line near the compressor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5474 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the electronic cycling clutch switch, the low pressure cut-off switch, and the Heater-A/C controls between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch ON and OFF. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts will open when the discharge line pressure rises above about 3100 - 3375 kPa (450 - 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 - 2275 kPa (270 - 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. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5475 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the dual function high pressure switch, or the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure switch wire harness connector from the switch on the refrigerant system fitting. 3. On the dual function high pressure switch, check for continuity between terminals C and D. On the two terminal switch, check for continuity between both terminals of the high pressure cut-off switch. There should be continuity. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5476 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations The low pressure cut-off switch is located on the suction line jumper tube. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5480 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The low pressure cut-off switch is located on the suction line jumper tube. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The fitting is equipped with an O-ring to seal the switch connection. The low pressure cut-off switch is connected in series electrically with the high pressure cut-off switch, the heater-A/C controls, the Electronic Cycling Clutch Switch (ECCS), between ground, 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 refrigerant system pressure, ensuring a sufficient amount of refrigerant throughout the system. The low pressure cut-off switch contacts will open when the suction pressure is about 48 to 90 kPa (7 to 13 psi) or lower. The switch contacts will close when the suction pressure rises to about 103 to 193 kPa (15 to 28 psi) or above. Lower ambient temperatures, below about -1 °C (30 °F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cut-off switch is a factory-calibrated unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5481 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the low pressure cut-off switch, remember that lower ambient temperatures, below about -1 °C (30 °F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. Also verify that the refrigerant system has the correct refrigerant charge. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cut-off switch wire harness connector from the switch on the suction line jumper fitting. 3. Install a jumper wire between the two cavities of the low pressure cut-off switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cut-off switch. There should be continuity with a suction pressure (low side) reading of 48 to 193 kPa (15 to 28 psi) or above, and no continuity with a suction pressure reading of 90 kPa (13 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5482 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cut-off switch on the suction line jumper near the expansion valve. 3. Unscrew the low pressure cut-off switch from the fitting on the suction line jumper. 4. Remove the O-ring seal from the suction line jumper fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the suction line jumper fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cut-off switch on the suction line jumper fitting. The switch should be hand-tightened onto the fitting. 3. Plug the wire harness connector into the low pressure cut-off switch. 4. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5486 Service Port HVAC: Description and Operation The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the liquid line between the condenser and the evaporator, near the front of the engine compartment. The low pressure service port is located on the compressor manifold, directly over the suction port of the compressor. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations Vacuum Check Valve HVAC: Locations One check valve is located near the vacuum fitting on the power brake booster. The second check valve is located at the heater and air conditioner take-out of the accessory vacuum supply line. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5490 Vacuum Check Valve HVAC: Description and Operation Two vacuum check valves are installed in the accessory vacuum supply line in the engine compartment. One check valve is located near the vacuum fitting on the power brake booster. The second check valve is located at the heater and air conditioner take-out of the accessory vacuum supply line. The vacuum check valves are designed to allow vacuum to flow in only one direction through the accessory vacuum supply circuits. The use of the vacuum check valves help to maintain the system vacuum needed to retain the selected heater-A/C mode settings. The check valves will prevent the engine from bleeding down system vacuum through the intake manifold during extended heavy engine load (low engine vacuum) operation. The vacuum check valves cannot be repaired and, if faulty or damaged, they must be individually replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5491 Vacuum Check Valve HVAC: Testing and Inspection 1. Remove the vacuum check valve that is to be tested. The valves are located in the vacuum supply tube (black) at the power brake booster on the left side of the engine compartment, and in the heater and air conditioner vacuum take-out of the vacuum supply tube in the engine compartment. The vacuum check valve must be removed in order to perform the following tests. 2. Connect the test set vacuum supply hose to the heater-A/C control side of the valve. When connected to this side of the check valve, no vacuum should pass and the test set gauge should return to the 27 kPa (8 in. Hg.) setting. If OK, go to step Step 3. If not OK, replace the faulty valve. 3. Connect the test set vacuum supply hose to the engine vacuum side of the valve. When connected to this side of the check valve, vacuum should flow through the valve without restriction. If not OK, replace the faulty valve. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 5492 Vacuum Check Valve HVAC: Service and Repair REMOVAL AND INSTALLATION Vacuum Supply 1. Unplug the vacuum supply line connector at the vacuum check valve. 2. Note the orientation of the check valve in the vacuum supply line for correct reinstallation. 3. Unplug the vacuum check valve from the vacuum supply line fittings. 4. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications Vacuum Reservoir HVAC: Specifications Vacuum Reservoir Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5496 Vacuum Reservoir HVAC: Locations The vacuum reservoir is mounted to the underside of the cowl plenum cover/grille panel in the right cowl plenum area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5497 Vacuum Reservoir HVAC: Description and Operation The vacuum reservoir is mounted to the underside of the cowl plenum cover/grille panel in the right cowl plenum area. The cowl plenum cover/grille panel must be removed from the vehicle to access the vacuum reservoir for service. Engine vacuum is stored in the vacuum reservoir. The stored vacuum is used to operate the vacuum controlled vehicle accessories during periods of low engine vacuum such as when the vehicle is climbing a steep grade, or under other high engine load operating conditions. The vacuum reservoir cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5498 Vacuum Reservoir HVAC: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. Cowl Plenum Cover/Grille Panel Weatherstip 3. Remove the weatherstrip along the front edge of the cowl plenum cover/grille panel and the cowl plenum panel. Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the one plastic rivet that secures the front corner on each side of the cowl plenum coven grille panel to the cowl plenum panel. 6. Remove the one plastic push-in retainer that secures the rear corner on each side of the cowl plenum cover/grille panel to the windshield reveal molding. 7. Unsnap the slotted center hole on each side of the cowl plenum cover/grille panel from the adhesive-backed snap fastener. (If equipped: This feature may not be on all models). 8. Lift the cowl plenum cover/grille panel from the cowl top far enough to access the windshield washer nozzle and vacuum plumbing near the right end of the cowl plenum. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Specifications > Page 5499 9. Disconnect the windshield washer supply hose at the in-line connector. Vacuum Reservoir 10. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured to the underside of the right end of the cowl plenum cover/grille panel. 11. Remove the cowl plenum cover/grille panel from the vehicle. 12. Remove the three screws that secure the vacuum reservoir to the underside of the cowl plenum cover/grille panel. 13. Remove the vacuum reservoir from the cowl plenum cover/grille panel. 14. Reverse the removal procedures to install. Tighten the vacuum reservoir mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System NON-DEPLOYED At no time should any source of electricity be permitted near the inflator on the back of an airbag module. When carrying a non-deployed airbag module, the trim cover or airbag side of the module should be pointed away from the body to minimize injury in the event of an accidental deployment. If the module is placed on a bench or any other surface, the trim cover or airbag side of the module should be face up to minimize movement in the event of an accidental deployment. In addition, the airbag system should be disarmed whenever any steering wheel, steering column, or instrument panel components require diagnosis or service. Failure to observe this warning could result in accidental airbag deployment and possible personal injury. Disposal Of Non-Deployed Airbag Modules All damaged or faulty and non-deployed driver side or passenger side airbag modules which are replaced on vehicles are to be returned. If an airbag module assembly is faulty or damaged and non-deployed, refer to the parts return list in the current Chrysler Corporation Warranty Policies and Procedures for the proper handling and disposal procedures. DEPLOYED Any vehicle which is to be returned to use after an airbag deployment, must have both airbag modules, the instrument panel assembly, the steering column assembly and the clockspring replaced. These components will be damaged or weakened as a result of an airbag deployment, which may or may not be obvious during a visual inspection, and are not intended for reuse Other vehicle components should be closely inspected, but are to be replaced only as required by the extent of the visible damage incurred. STORAGE An airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store an airbag module on a surface with its trim cover or airbag side facing up, to minimize movement in case of an accidental deployment. Wear Safety Glasses And Rubber Gloves - Typical CLEANUP PROCEDURE Following an airbag system deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge used to initiate the airbag deployment propellant. However, this residue will also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the nitrogen gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be sure to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: IF YOU EXPERIENCE SKIN IRRITATION DURING CLEANUP, RUN COOL WATER OVER THE AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. Begin the cleanup by removing the airbag modules from the vehicle. Refer to Driver Side Airbag Module and Passenger Side Airbag Module in the Removal and Installation. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5505 Vacuum Heater And A/C Outlets - Typical Be sure to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Place the deployed airbag modules in your vehicular scrap pile. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5506 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5511 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service Air Bag: Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5516 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5517 Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver Airbag - Trim Cover Service > Page 5518 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5519 Air Bag: Specifications Driver Side Airbag Module Mounting Screws 10.2 Nm Driver Side Trim Cover Retainer Mounting Nuts 10 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5520 Air Bag: Diagrams Driver Airbag Squib Passenger Airbag Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5521 Air Bag: Service Precautions WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES,THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER.FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER SIDE AIRBAG MODULE TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALSO, METAL SHAVINGS CREATED WHEN DRILLING COULD ENTER THE PASSENGER SIDE AIRBAG MODULE AND RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER SIDE AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT INSTRUMENT PANEL ASSEMBLIES AND TOP COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE PASSENGER SIDE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5522 Air Bag: Description and Operation DRIVER SIDE AIRBAG MODULE The driver side airbag module protective trim cover is the most visible part of the driver side airbag system. The driver side airbag module is mounted directly to the steering wheel. Located under the air- bag module trim cover are the horn switch, the folded airbag cushion, and the airbag cushion supporting components. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the airbag module trim cover, between the trim cover and the folded airbag cushion. The driver side airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The driver side airbag module trim cover and the horn switch are available as a unit for service replacement. The driver side airbag module includes a stamped metal housing to which the cushion and an inflator unit are attached and sealed. The conventional pyrotechnic-type inflator assembly is mounted to studs on the back of the airbag module housing. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas towards the instrument panel through the porous fabric material used on the steering wheel side of the airbag cushion. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The inside of the trim cover has locking blocks molded into it that engage a lip on the airbag module metal housing. Two stamped metal retainers then fit over the inflator mounting studs on the back of the airbag module housing and are engaged in slots on the inside of the cover, securely locking the trim cover into place. The trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch upon airbag deployment. PASSENGER SIDE AIRBAG MODULE The passenger side airbag door on the instrument panel above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door are the passenger side airbag cushion and the airbag cushion supporting components. The passenger side airbag module includes an extruded aluminum housing within which the cushion and inflator are mounted and sealed. The airbag housing extrusion also includes two flanges. The flanges, one at the top and one at the bottom, serve as the mounting brackets for the module. Two stamped metal brackets, one on each end of the housing, enclose the cushion and inflator. The passenger side airbag module upper bracket is secured beneath the instrument panel top pad with rivets to a flange and bracket on the passenger side airbag door. The lower bracket is secured with screws to the instrument panel structural duct. Following a passenger side airbag deployment, the passenger side airbag module and the instrument panel assembly must be replaced. The passenger side airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas through the porous fabric material used on each end panel of the airbag cushion. The molded plastic passenger side airbag door is secured to the instrument panel top cover with rivets. The airbag door has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The passenger side airbag door is serviced only as a unit with the instrument panel top cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag The following procedure is for replacement of a faulty or damaged driver side airbag module. If the driver side airbag has been deployed, the clockspring and the steering column assembly must also be replaced. Refer to Clockspring for the additional service procedures for the clockspring. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES,THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. Driver Side Airbag Module Remove/Install 2. From the underside of the steering wheel, remove the two screws that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the two wire harness connectors on the back of the airbag module. 4. Disconnect the clockspring horn switch wire harness connector from the horn switch feed wire connector, which is located on the back of the airbag module. 5. The clockspring airbag wire harness connector is a tight snap-fit into the airbag module connector receptacle, which is located on the airbag inflator on the back of the airbag module. Firmly grasp and pull or gently pry on the clockspring airbag wire harness connector to disconnect it from the airbag module. Do not pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 6. Remove the driver side airbag module from the steering wheel. 7. If the driver side airbag has been deployed, the clockspring and the steering column must be replaced. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER.FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5525 - THE DRIVER SIDE AIRBAG MODULE TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. When installing the driver side airbag module, reconnect the clockspring airbag wire harness connector to the airbag module connector receptacle by pressing straight in on the connector. You can be certain that the connector is fully engaged by listening carefully for a distinct audible click as the connector snaps into place. 2. Reconnect the clockspring horn switch wire harness connector to the horn switch feed wire connector, which is located on the back of the airbag module. 3. Carefully position the driver side airbag module in the steering wheel. Be certain that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 4. From the underside of the steering wheel, install and tighten the two driver side airbag module mounting screws. Tighten the screws to 10.2 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5526 Air Bag: Service and Repair Driver Airbag Cover The horn switch is integral to the driver side airbag module trim cover. If either component is faulty or damaged, the entire driver side airbag module trim cover and horn switch unit must be replaced. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIR-BAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. Driver Side Airbag Trim Cover Retainer Nuts Remove/Install 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver side airbag housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5527 Driver Side Airbag Trim Cover Retainers Remove/Install 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the upper airbag housing stud. Driver Side Airbag Trim Cover Remove/Install 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the driver side airbag housing and remove the housing from the cover. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER.FAILURE Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5528 TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE DRIVER SIDE AIRBAG MODULE TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the driver side airbag module in the trim cover. Be certain that the horn switch feed and ground wires are not pinched between the airbag housing and the trim cover locking blocks. Driver Side Airbag Trim Cover Locking Blocks Engaged 2. Engage the upper and lower trim cover locking blocks with the lip of the driver side airbag housing, then engage the locking blocks on each side of the trim cover with the lip of the housing. Be certain that each of the locking blocks is fully engaged on the lip of the airbag housing. 3. Install the horn switch ground wire eyelet over the upper airbag housing stud. 4. Install the upper and lower airbag trim cover retainers over the airbag housing studs. Be certain that the tabs on each retainer are engaged in the retainer slots of the upper and lower trim cover locking blocks. 5. Install and tighten the trim cover retainer mounting nuts on the airbag housing studs. Tighten the nuts to 10 Nm (90 in. lbs.). 6. Install the driver side airbag module onto the steering wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5529 Air Bag: Service and Repair Passenger Airbag The following procedure is for replacement of a faulty or damaged passenger side airbag module. If the passenger side airbag module has been deployed, the instrument panel assembly must be replaced. The instrument panel assembly includes the passenger side airbag module and the passenger side airbag door. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES,THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the instrument panel top cover and the passenger side airbag module from the instrument panel as a unit. 3. Place the instrument panel top cover assembly on a suitable work surface. Be certain to take the proper precautions to protect the top cover from any possible cosmetic damage. Passenger Side Airbag Module Vents 4. Apply masking tape over the passenger side airbag module vents on each end of the module. The tape will help to prevent foreign material from entering the airbag module through the vents during removal and installation of the module from the upper airbag door flange and bracket. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE INSTRUMENT PANEL TOP COVER AND THE PASSENGER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5530 Passenger Side Airbag Module Rivets 5. Using a suitable center punch, carefully drive out the mandrels from the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the instrument panel top cover. 6. Use a suitable pair of rivet cutters or a large pair of side cutters to cut the rims or heads off of the four rivets that secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover. WARNING: DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALSO, METAL SHAVINGS CREATED WHEN DRILLING COULD ENTER THE PASSENGER SIDE AIRBAG MODULE AND RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Passenger Side Airbag Module Remove/Install 7. Remove the passenger side airbag module from the upper airbag door flange and bracket on the underside of the instrument panel top cover. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE PASSENGER SIDE AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - THE PASSENGER SIDE AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT INSTRUMENT PANEL ASSEMBLIES AND TOP COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE PASSENGER SIDE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5531 THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket on the underside of the instrument panel top cover. NOTE: Use only the correct rivets that are specified in the Chrysler Mopar Parts Catalog, or that are supplied in the service package with the new airbag module and/or the new instrument panel top cover when installing the passenger side airbag module. 2. Secure the passenger side airbag module upper mounting bracket to the upper airbag door flange and bracket with four rivets. 3. Remove the masking tape applied to the passenger side airbag module vents during the removal procedures. 4. Install the instrument panel top cover and the passenger side airbag module onto the instrument panel as a unit. 5. Be certain that the passenger side airbag module wire harness connector is fully engaged with and latched to the instrument panel wire harness connector. 6. Do not reconnect the battery negative cable at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM Mounting Screws 11.8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5535 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5536 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5537 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5538 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5539 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the center support bracket from the instrument panel. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 5540 5. Do not reconnect the battery negative cable at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5545 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.** Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5546 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5547 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5548 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5549 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5550 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 5551 Passenger Airbag On/Off Switch - C1 (Switch Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement Technical Service Bulletin # 982 Date: 010601 Recall - Clockspring Replacement June 2001 Safety Recall No. 982 - Clockspring Models 2000-2001 (BR/BE) Dodge Ram Pickup Trucks NOTE: This recall applies only to the above vehicles built at the: > Warren Assembly Plant ("S" in the 11th position) from May 16, 2000 through October 23, 2000 (MDH 0516XX through 102300) > St. Louis North Assembly Plant ("J" in the 11th VIN position) from May 19, 2000 through October 23, 2000 (MDH 0519XX through 102300) > Lago Alberto Assembly Plant ("M" in the 11th VIN position) from May 23, 2000 through October 23, 2000 (MDH 0523XX through 102300) > Saltillo Assembly Plant ("G" in the 11th VIN position) from May 23, 2000 through October 23, 2000 (MDH 0523XX through 102310) 2000 (AN) Dodge Dakota Trucks NOTE: This recall applies only to the above vehicles built from May 16, 2000 through July 5, 2000 (MDH 0516XX through 0705XX). 2000 (DN) Dodge Durango Trucks NOTE: This recall applies only to the above vehicles built from May 13 2000 through July 24, 2000 (MDH 0523XX through 0724XX). IMPORTANT: Vehicles that have already had the proper clockspring installed, according to warranty records, have been excluded from this recall. In addition, 1997 - 2001 model year vehicles that have had a suspect replacement clockspring installed, according to warranty records, have been added to this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The clockspring on about 200,000 of the above vehicles may break. This could cause the driver's airbag, speed control and steering wheel mounted audio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver under certain accident conditions. Repair The clockspring assembly must be replaced Parts Information No parts will be distributed initially for this recall. Dealers should order enough of each clockspring as necessary to support scheduled repairs. Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The clockspring for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5560 > Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the part 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 MDS2 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 have been entered to DIAL System Functions 53 and VIP 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 "0RD982". 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5561 Vehicle Not Available 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: 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. Service Procedure 1. Place the front wheels in the straight-ahead position. 2. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 3. From the backside of the steering wheel, remove the two (2) screws that secure the driver's airbag module to the steering wheel (Figure 1). 4. Pull the airbag module away from the steering wheel far enough to access the two (2) wire harness connectors on the back of the airbag module. 5. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 1). 6. Disconnect the clockspring airbag wire harness connector (Figure 1) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 7. Remove the airbag module and set it aside. 8. Disconnect the clockspring wire harness connectors from the speed control switches and remote audio control switches (if equipped). NOTE: Remove the speed control switches from the steering wheel to access the connectors if necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5562 9. Remove the steering wheel nut. 10. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 11. Remove the three (3) screws that secure the lower edge of the steering column opening cover (Figure 2). 12. Using a trim stick, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column to disengage the snap clip retainers. Set the cover aside. 13. Remove the tilt steering column adjuster lever (if equipped). 14. Remove the upper and lower shrouds from the steering column (Figure 3). 15. Disconnect the instrument panel wire harness connector from the lower clockspring connector receptacle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5563 16. Disconnect the clockspring wire harness connector from the instrument panel wire harness, located on the instrument panel lower reinforcement below the steering column. 17. Remove and discard the clockspring from the steering column by carefully disengaging the plastic latches. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the steering column lock housing. 19. Connect the clockspring wire harness connector to the instrument panel wire harness. 20. Connect the instrument panel wire harness connector to the lower clockspring connector receptacle. 21. Install the upper and lower shrouds onto the steering column (Figure 3). 22. Install the tilt steering column adjuster lever (if equipped). 23. Install the steering column opening cover and engage the snap clip retainers. 24. Install the three (3) screws that secure the lower edge of the steering column opening cover (Figure 2). Tighten the screws to 20 in-lbs (2.2 N.m). 25. Install the steering wheel onto the steering column shaft. 26. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 27. Connect the clockspring wire harness connectors to the speed control switches and remote audio control switches (if equipped). 28. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 1). 29. Connect the clockspring horn switch wire harness connector to the horn switch feed wire connector on the back of the airbag module (Figure 1). 30. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 31. From the backside of the steering wheel, install the two (2) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 90 in-lbs (10 N.m). 32. With the ignition switch in the ON position, connect the negative battery cable. 33. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 34. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5564 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA01V153000 > Apr > 01 > Recall 01V153000: Clockspring Assembly Clockspring Assembly / Spiral Cable: Recalls Recall 01V153000: Clockspring Assembly Vehicle Description: Pickup trucks. Sound deadener material inside the steering wheel could become detached from the cover and housing. When this occurs, the material could interfere with the clockspring ribbon and cause an open circuit. The driver air bag system will become disabled, and the air bag warning lamp will illuminate on the instrument panel. Dealers will replace the clockspring assembly. Owner notification began June 18, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement Technical Service Bulletin # 982 Date: 010601 Recall - Clockspring Replacement June 2001 Safety Recall No. 982 - Clockspring Models 2000-2001 (BR/BE) Dodge Ram Pickup Trucks NOTE: This recall applies only to the above vehicles built at the: > Warren Assembly Plant ("S" in the 11th position) from May 16, 2000 through October 23, 2000 (MDH 0516XX through 102300) > St. Louis North Assembly Plant ("J" in the 11th VIN position) from May 19, 2000 through October 23, 2000 (MDH 0519XX through 102300) > Lago Alberto Assembly Plant ("M" in the 11th VIN position) from May 23, 2000 through October 23, 2000 (MDH 0523XX through 102300) > Saltillo Assembly Plant ("G" in the 11th VIN position) from May 23, 2000 through October 23, 2000 (MDH 0523XX through 102310) 2000 (AN) Dodge Dakota Trucks NOTE: This recall applies only to the above vehicles built from May 16, 2000 through July 5, 2000 (MDH 0516XX through 0705XX). 2000 (DN) Dodge Durango Trucks NOTE: This recall applies only to the above vehicles built from May 13 2000 through July 24, 2000 (MDH 0523XX through 0724XX). IMPORTANT: Vehicles that have already had the proper clockspring installed, according to warranty records, have been excluded from this recall. In addition, 1997 - 2001 model year vehicles that have had a suspect replacement clockspring installed, according to warranty records, have been added to this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The clockspring on about 200,000 of the above vehicles may break. This could cause the driver's airbag, speed control and steering wheel mounted audio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver under certain accident conditions. Repair The clockspring assembly must be replaced Parts Information No parts will be distributed initially for this recall. Dealers should order enough of each clockspring as necessary to support scheduled repairs. Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The clockspring for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5574 > Entering the VIN into the DIAL VIP System (sales code information) along with the table (all dealers) shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the part 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 MDS2 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 have been entered to DIAL System Functions 53 and VIP 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 "0RD982". 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5575 Vehicle Not Available 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: 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. Service Procedure 1. Place the front wheels in the straight-ahead position. 2. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 3. From the backside of the steering wheel, remove the two (2) screws that secure the driver's airbag module to the steering wheel (Figure 1). 4. Pull the airbag module away from the steering wheel far enough to access the two (2) wire harness connectors on the back of the airbag module. 5. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 1). 6. Disconnect the clockspring airbag wire harness connector (Figure 1) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 7. Remove the airbag module and set it aside. 8. Disconnect the clockspring wire harness connectors from the speed control switches and remote audio control switches (if equipped). NOTE: Remove the speed control switches from the steering wheel to access the connectors if necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5576 9. Remove the steering wheel nut. 10. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 11. Remove the three (3) screws that secure the lower edge of the steering column opening cover (Figure 2). 12. Using a trim stick, gently pry the upper edge of the steering column opening cover just below the cluster bezel on each side of the steering column to disengage the snap clip retainers. Set the cover aside. 13. Remove the tilt steering column adjuster lever (if equipped). 14. Remove the upper and lower shrouds from the steering column (Figure 3). 15. Disconnect the instrument panel wire harness connector from the lower clockspring connector receptacle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5577 16. Disconnect the clockspring wire harness connector from the instrument panel wire harness, located on the instrument panel lower reinforcement below the steering column. 17. Remove and discard the clockspring from the steering column by carefully disengaging the plastic latches. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the steering column lock housing. 19. Connect the clockspring wire harness connector to the instrument panel wire harness. 20. Connect the instrument panel wire harness connector to the lower clockspring connector receptacle. 21. Install the upper and lower shrouds onto the steering column (Figure 3). 22. Install the tilt steering column adjuster lever (if equipped). 23. Install the steering column opening cover and engage the snap clip retainers. 24. Install the three (3) screws that secure the lower edge of the steering column opening cover (Figure 2). Tighten the screws to 20 in-lbs (2.2 N.m). 25. Install the steering wheel onto the steering column shaft. 26. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 27. Connect the clockspring wire harness connectors to the speed control switches and remote audio control switches (if equipped). 28. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 1). 29. Connect the clockspring horn switch wire harness connector to the horn switch feed wire connector on the back of the airbag module (Figure 1). 30. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 31. From the backside of the steering wheel, install the two (2) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 90 in-lbs (10 N.m). 32. With the ignition switch in the ON position, connect the negative battery cable. 33. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 34. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 982 > Jun > 01 > Recall - Clockspring Replacement > Page 5578 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5583 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA01V153000 > Apr > 01 > Recall 01V153000: Clockspring Assembly Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 01V153000: Clockspring Assembly Vehicle Description: Pickup trucks. Sound deadener material inside the steering wheel could become detached from the cover and housing. When this occurs, the material could interfere with the clockspring ribbon and cause an open circuit. The driver air bag system will become disabled, and the air bag warning lamp will illuminate on the instrument panel. Dealers will replace the clockspring assembly. Owner notification began June 18, 2001. 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 DaimlerChrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5593 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5594 Clockspring Assembly / Spiral Cable: Diagrams Clockspring No. 1 - C1 Clockspring No.1 - C2 Clockspring No. 2 Clockspring Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5595 Clockspring Assembly / Spiral Cable: Service Precautions WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5596 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring assembly is secured with two integral plastic latches onto the steering column lock housing near the top of the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the fixed clockspring wire harness on the steering column and several electrical components that rotate with the steering wheel. The rotating components include the driver side airbag module, the horn switch and, if the vehicle is so equipped, the vehicle speed control switches and/or the remote radio switches. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver side airbag has been deployed, the clockspring must be replaced. The clockspring assembly consists of a plastic case which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds like a clockspring with the steering wheel rotation. The electrically conductive tape consists of several fine gauge copper wire leads sandwiched between two narrow strips of plastic film. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear allowing the clockspring tape to change position relative to the other steering components, it must be re-centered following completion of the service or it may be damaged. Service replacement clocksprings are shipped pre-centered and with a piece of tape covering the depressed clockspring auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5597 Clockspring Assembly / Spiral Cable: Adjustments The clockspring is designed to wind and unwind when the steering wheel is rotated, but is only designed to rotate the same number of turns (about five complete rotations) as the steering wheel can be turned from stop to stop. Centering the clockspring indexes the clockspring tape to other steering components so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape. However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change position relative to the other steering components. The clockspring must then be re-centered following completion of the service or the clockspring tape may be damaged. Service replacement clocksprings are shipped precentered and with a piece of tape covering the depressed auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND)CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT ACCIDENTAL AIRBAG AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. Fig. 43 Auto-locking clockspring 3. Depress the two plastic clockspring auto-locking tabs. 4. Keeping the auto-locking tabs depressed, rotate the clockspring hub clockwise to the end of its travel. Do not apply excessive torque. 5. From the end of the clockwise travel, rotate the hub about two and one-half turns counterclockwise, then release the auto-locking tabs. The clockspring horn wire harness should end up at the top, and the airbag, optional speed control and optional remote radio wire harnesses at the bottom. 6. The front wheels should still be in the straight ahead position. Install the clockspring onto the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5598 Clockspring Assembly / Spiral Cable: Service and Repair The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver side airbag has been deployed. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the driver side airbag module from the steering wheel. 3. If the vehicle is so equipped, disconnect the upper clockspring wire harness connectors from the vehicle speed control switches and the remote radio switches located within the hub cavity of the steering wheel. 4. Remove the nut that secures the steering wheel armature to the steering column upper shaft, which is located within the hub cavity of the steering wheel. 5. Pull the steering wheel off of the steering column upper shaft spline using a steering wheel puller (Special Tool C-3428-B). 6. Remove the steering column opening cover from the instrument panel. 7. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 8. Remove both the upper and lower shrouds from the steering column. 9. Remove the lower fixed column shroud from the steering column. 10. Remove the two tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the left side of the steering column lock housing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5599 Clockspring Latches 11. Gently pull the multi-function switch away from the left side of the steering column lock housing far enough to access the side latch of the clockspring assembly. 12. Disconnect the instrument panel wire harness connector from the lower clockspring connector receptacle. 13. Disconnect the lower clockspring wire harness connector from the instrument panel wire harness, located on the instrument panel lower reinforcement below the steering column. CAUTION: Failure to disengage the plastic latches of the clockspring from the receptacles in the steering column lock housing prior to clockspring removal will result in damage to the clockspring latches. 14. Using a small screwdriver, gently pry under the plastic latches at the side and the top of the clockspring assembly to disengage them from the receptacles in the steering column lock housing and remove the clockspring from the column. The clock- spring cannot be repaired. It must be replaced if faulty or damaged, or if the driver side airbag has been deployed. INSTALLATION If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. Service replacement clocksprings are shipped precentered and with a piece of tape covering the depressed clockspring auto-locking tabs. This tape should not be removed until the clockspring has been installed on the steering column. If the tape is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. Carefully slide the centered clockspring down over the steering column upper shaft until the plastic latches at the side and the top of the clockspring assembly latches engage the receptacles in the steering column lock housing. 2. Reconnect the lower clockspring wire harness connector to the instrument panel wire harness. Be certain that the wire harness locator clips are properly seated on the outside of the wiring trough and that the connector latches are fully engaged. 3. Reconnect the instrument panel wire harness connector to the lower clockspring connector receptacle. 4. Position the multi-function switch onto the left side of the steering column lock housing. 5. Install and tighten the two screws that secure the multi-function switch to the left side of the steering column lock housing. Tighten the screws to 2 Nm (17 in. lbs.). 6. Install the steering column shrouds. Be certain that the lower clockspring wire harness is routed inside the shrouds. 7. Install the steering column opening cover onto the instrument panel. 8. Install the steering wheel onto the steering column upper shaft. Be certain to index the flats on the hub of the steering wheel with the formations on the inside of the clockspring hub. Pull the upper clock- spring wire harnesses through the upper and lower holes between the steering wheel back trim cover and the steering wheel armature. 9. Install and tighten the steering wheel mounting nut. Tighten the nut to 61 Nm (45 ft. lbs.). Be certain not to pinch the wire harnesses between the steering wheel and the nut. 10. If the vehicle is so equipped, reconnect the upper clockspring wire harness connectors to the vehicle speed control switches and/or the remote radio switches. Be certain that the upper clockspring wire harnesses are routed between the steering wheel back trim cover and the steering wheel armature. 11. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 12. Install the driver side airbag module onto the steering wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Application and ID Malfunction Lamp / Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Airbag .................................................................................................................................................. .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5607 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5608 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5609 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5610 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5611 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications ACM Mounting Screws 11.8 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5616 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5617 Airbag Control Module Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5618 Air Bag Control Module: Service Precautions WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5619 Air Bag Control Module: Description and Operation The Airbag Control Module (ACM) is secured with screws to a mount welded onto the floor panel transmission tunnel behind the instrument panel center support bracket in the passenger compartment of the vehicle. The ACM contains an electronic microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the ACM contains the airbag system logic. The airbag system logic includes On-Board Diagnostics (OBD), and the ability to communicate with the instrument cluster circuitry over the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor continuously monitors all of the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster over the CCD data bus to turn on the airbag indicator lamp. One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor 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 airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5620 Air Bag Control Module: Service and Repair WARNING: - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. - FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. REMOVAL 1. Disconnect and isolate the battery negative cable. If either of the airbags has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the center support bracket from the instrument panel. Airbag Control Module Remove/Install 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. 4. Disconnect the instrument panel wire harness connector from the Airbag Control Module (ACM). To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the vehicle. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. Remove the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. 6. Remove the ACM from the mount on the floor panel transmission tunnel. INSTALLATION 1. Carefully position the ACM to the mount that is welded onto the floor panel transmission tunnel. When the ACM is correctly positioned the arrow on the ACM label will be pointed forward in the vehicle. 2. Install and tighten the three screws that secure the ACM to the mount that is welded onto the floor panel transmission tunnel. Tighten the screws to 11.8 Nm (105 in. lbs.). 3. Install and tighten the screw that secures the instrument panel wire harness ground eyelet to the left side of the mount that is welded onto the floor panel transmission tunnel. Tighten the screw to 3.4 Nm (30 in. lbs.). 4. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. Be certain that the connector latch and the red CPA lock are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 5621 5. Do not reconnect the battery negative cable at this time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5626 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5632 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5633 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5634 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5635 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5636 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5637 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5638 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5639 detailed instruction sheet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5640 PARTS REQUIRED: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5641 POLICY: Customer Satisfaction Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5642 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5643 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5644 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5645 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5646 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5647 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5648 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The driver seat belt switch is integral to the driver seat belt retractor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5652 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5653 Seat Belt Buckle Switch: Description and Operation DRIVER SEAT BELT SWITCH The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half the switch opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5654 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Fasten Seat Belts ................................................................................................................................ ..................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5663 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.** Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5664 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5665 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5666 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5667 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5668 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 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 5669 Passenger Airbag On/Off Switch - C1 (Switch Side) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations The driver seat belt switch is integral to the driver seat belt retractor assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5673 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5674 Seat Belt Buckle Switch: Description and Operation DRIVER SEAT BELT SWITCH The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half the switch opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5675 Seat Belt Buckle Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the driver seat belt retractor. Check for continuity between the circuit cavity in the body half of the driver seat belt switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit as required. 2. Check for continuity between the two cavities in the seat belt half of the driver seat belt switch wire harness connector. There should be no continuity with the seat belt webbing retracted, and continuity with the seat belt webbing pulled out of the retractor far enough to engage the seat belt buckle. If OK, go to Step 3. If not OK, replace the faulty driver side seat belt and retractor assembly. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavities of the instrument cluster wire harness connector (connector B) and the body half of the driver seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Cluster in the Diagnosis and Testing for diagnosis of the chime request circuit. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Antenna Body And Cable 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. Antenna Coaxial Cable Routing 3. Reach under the instrument panel below the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 4. Disengage the antenna coaxial cable from the retainer clips on the lower instrument panel reinforcement and the heater-A/C housing. 5. Disengage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 5682 Antenna Mast Remove/Install - Typical 6. Unscrew the antenna mast from the antenna body. Antenna Cap Nut Remove/Install - Typical 7. Remove the antenna cap nut using an antenna nut wrench (Special Tool C-4816). 8. Remove the antenna adapter from the top of the fender. 9. Lower the antenna body through the mounting hole in the top of the fender. Antenna Mounting Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 5683 10. Pull the antenna body and cable out through the opening between the right cowl side outer panel and the fender through the front door opening. 11. Disengage the antenna coaxial cable grommet from the hole in the right cowl side outer panel. 12. Pull the antenna coaxial cable out of the passenger compartment through the hole in the right cowl side outer panel. 13. Remove the antenna body and cable from the vehicle. Instrument Panel Antenna Cable 1. Disconnect and isolate the battery negative cable. 2. Reach under the instrument panel below the glove box to access and disconnect the antenna coaxial cable connector. Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 3. Securely tie a suitable length of cord or twine to the instrument panel half of the antenna coaxial cable connector. This cord will be used to pull or "fish" the cable back into position during installation. 4. Disengage the instrument panel antenna cable from the retainer clip on the lower instrument panel reinforcement inboard of the glove box opening. 5. Roll down the glove box from the instrument panel. 6. Reach through the glove box opening to access and disengage the retainer that secures the antenna cable to the instrument panel structural support on the inboard side of the glove box opening. 7. Remove the radio receiver from the instrument panel. 8. Pull the antenna cable out through the radio receiver opening in the instrument panel. 9. Untie the cord or twine from the instrument panel antenna cable connector, leaving the cord or twine in place of the cable in the instrument panel. 10. Remove the antenna cable from the instrument panel. INSTALLATION Antenna Body And Cable 1. Position the antenna body and cable in the opening between the right cowl side outer panel and the fender through the front door opening. 2. Push the antenna coaxial cable into the passenger compartment through the hole in the right cowl side outer panel. 3. Engage the antenna coaxial cable grommet in the hole in the right cowl side outer panel. 4. Position the antenna body through the mounting hole in the top of the fender. 5. Install the adapter over the antenna body from the top of the fender. 6. Install and tighten the antenna cap nut using an antenna nut wrench (Special Tool C-4816). Tighten the antenna cap nut to 8 Nm (70 in. lbs.). 7. Install and tighten the antenna mast onto the antenna body. Tighten the mast to 3.3 Nm (30 in. lbs.). 8. Engage the antenna coaxial cable retainers at the right cowl side inner panel and inside the right front fender. 9. Engage the antenna coaxial cable in the retainer clips on the lower instrument panel reinforcement and the heater-A/C housing. 10. Reach under the instrument panel below the glove box to reconnect the antenna coaxial cable connector. 11. Install the trim cover onto the right cowl side inner panel. 12. Reconnect the battery negative cable. Instrument Panel Antenna Cable 1. Tie the end of the cord or twine that was used during instrument panel antenna cable removal securely to the connector on the end of the antenna coaxial cable being installed into the instrument panel. This cord will be used to pull or "fish" the cable back into position. 2. Using the cord or twine, pull the antenna cable through the radio receiver opening from under the instrument panel. 3. Install the radio receiver onto the instrument panel. 4. Reach through the glove box opening to access and engage the retainer that secures the antenna cable to the instrument panel structural support on the inboard side of the glove box opening. 5. Install the glove box onto the instrument panel. 6. Engage the instrument panel antenna cable to the retainer clip on the lower instrument panel reinforcement inboard of the glove box opening. 7. Untie the cord or twine from the instrument panel half of the antenna coaxial cable connector. 8. Reach under the instrument panel below the glove box to access and reconnect the antenna coaxial cable connector. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Driver Door Arm/Disarm Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Locations Door Sensor/Switch (For Alarm): Locations The door ajar switch is integral to the door latch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 5691 Door Sensor/Switch (For Alarm): Description and Operation The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 5692 Door Sensor/Switch (For Alarm): Service and Repair The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the high-line version of the Central Timer Module (CTM). The CTM also contains the program logic and control circuitry for the RKE system. The CTM is mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The RKE receiver has a memory function to retain the vehicle access codes of up to four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. The RKE receiver is energized by one of three radio frequency inputs from the RKE transmitter; Unlock, Lock, or Panic. The programming of the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, the driver unlock relay, the horn relay, and the headlamp relay. For diagnosis or programming of the RKE receiver within the high-line CTM, a DRB scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or another suitable wide fiat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation DOOR LOCK CYLINDER SWITCH The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are resistor multiplexed momentary switches that are hard wired between a body ground and the Central Timer Module (CTM) through the front door wire harnesses. These switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The door lock cylinder switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door lock cylinder switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the front door key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. LIFTGATE LOCK CYLINDER SWITCH The liftgate lock cylinder switch is mounted to the back of the liftgate key lock cylinder inside the liftgate. It is a resistor multiplexed momentary switch that is hard wired between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. This switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The liftgate lock cylinder switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate lock cylinder switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the liftgate key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test Lock Cylinder Switch: Testing and Inspection Door Lock Cylinder Switch Test 1. Disconnect the door lock cylinder switch wire harness connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Lock Cylinder Switch chart. 3. If a door lock cylinder switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test > Page 5706 Lock Cylinder Switch: Testing and Inspection Liftgate Lock Cylinder Switch Test 1. Disconnect the liftgate lock cylinder switch wire harness connector from the liftgate wire harness connector. Liftgate Lock Cylinder Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Lift-gate Lock Cylinder Switch chart. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement > Page 5709 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Security Lamp/Indicator: Locations The security lamp is located within the instrument cluster on the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5713 Security Lamp/Indicator: Description and Operation The security lamp is located within the instrument cluster on the instrument panel. The security lamp is illuminated by a red Light-Emitting Diode (LED) that is integral to the instrument cluster circuit board. The security lamp receives fused battery feed at all times and is grounded by the high-line Central Timer Module (CTM) to give a visual indication of the Vehicle Theft Security System (VTSS) arming status. The security lamp cannot be repaired and, if faulty or damaged, the instrument cluster unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 5714 Security Lamp/Indicator: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Security Lamp The diagnosis found here addresses an inoperative security lamp condition. If the problem being diagnosed is an inaccurate security lamp, refer to Vehicle Theft Security System. 1. Check the fused B(+) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM). Disconnect the CTM wire harness connectors. Connect the battery negative cable. Install a jumper wire between the VTSS indicator driver circuit cavity of the 18-way CTM wire harness connector and a good ground. The security lamp should light. If OK, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the Vehicle Theft Security System (VTSS) and the CTM. If not OK, go to Step 4. 4. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Check for continuity between the fused B(+) circuit cavity of the instrument cluster wire harness connector A and the fused B(+) fuse in the junction block. There should be continuity. If OK, go to Step 5. If not OK, repair the open fused B(+) circuit to the fuse in the junction block as required. 5. Check for continuity between the VTSS indicator driver circuit cavities of the instrument cluster wire harness connector A and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Self-Diagnostic Test. If not OK, repair the open VTSS indicator driver circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5718 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5723 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5724 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5725 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5730 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5731 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5732 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER STORAGE BIN A compartment near the rear of the overhead console is designed to hold most garage door opener remote control transmitters. The door for the garage door opener compartment features a spring-loaded latch mechanism and has a small depression with tactile ribs just forward of the latch. The transmitter is mounted within the compartment with an adhesive-backed hook and loop fastener patch and, when the compartment is closed, the depressed area of the compartment door is pressed upward to actuate the transmitter. A transmitter mounting kit including the adhesive backed hook and loop fastener material and additional adapter pegs is available for service. The garage door opener storage bin door is also available for service replacement. The door unit includes the spring-loaded latch mechanism. If any of these components is damaged or faulty, the garage door opener storage bin door unit must be replaced. The garage door opener storage compartment door is opened by pressing the spring-loaded latch towards the front of the vehicle. When the compartment door is opened, the garage door opener transmitter can be installed in the compartment using the adhesive-backed hook and loop fastener material provided. With the transmitter mounted in the storage bin, adapter pegs located on the inside of the garage door opener door are selected and mounted on one of several posts on the back side of the door. The adapter pegs can be stacked if additional length is required. The combination of the adapter peg length and the peg location selected must be suitable to depress the button of the transmitter when the center of the garage door opener storage bin door is depressed. When the proper combination has been selected, the compartment door is closed and need not be reopened except to replace the transmitter batteries. See the owner's manual in the vehicle glove box for more information on the use and operation of the overhead console garage door opener storage bin. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Page 5736 Garage Door Opener Transmitter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Garage Door Opener Storage Bin Door Remove/Install 3. Remove the two screws that secure the garage door opener storage bin door pivot and bumper block to the overhead console housing. 4. Remove the garage door opener storage bin door pivot and bumper block from the overhead console housing. 5. Unlatch and remove the garage door opener storage bin door from the overhead console housing. INSTALLATION 1. Position the garage door opener storage bin door into the overhead console housing. 2. Engage the latch of the garage door opener storage bin door with the latch striker on the rear of the storage bin opening in the overhead console housing. 3. Be certain that both garage door opener storage bin door pivot pins are located in the two pivot receptacles in the overhead console housing just behind the sunglasses storage bin. 4. Position the garage door opener storage bin door pivot and bumper block onto the overhead console housing. 5. Install and tighten the two screws that secure the garage door opener storage bin door pivot and bumper block to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the overhead console onto the headliner. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service Precautions Amplifier: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service Precautions > Page 5741 Amplifier: Description and Operation Models equipped with the Infinity premium speaker package have a separate power amplifier unit. This power amplifier is rated at 100 watts output. The power amplifier unit is mounted to the right cowl side inner panel under the passenger side end of the instrument panel. The power amplifier unit can be accessed for service by removing the trim from the right cowl side inner panel. The power amplifier unit should be checked if there is no sound output noted from the speakers. The power amplifier cannot be repaired or adjusted and, if faulty or damaged, the unit must be replaced. The power amplifier receives fused battery current from a fuse in the Junction Block (JB) at all times. The internal circuitry of the power amplifier switches the amplifier on based upon a fused 12 volt output signal that is received from the radio receiver whenever the radio is turned ON. The power amplifier receives the sound signal inputs for four speaker channels from the radio receiver, then sends the amplified speaker outputs for each of those channels to the eight speakers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service Precautions > Page 5742 Amplifier: Testing and Inspection The power amplifier unit should be checked if there is no sound output noted from the speakers. For diagnosis of the power amplifier, refer to Speaker in the Diagnosis and Testing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service Precautions > Page 5743 Amplifier: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the trim cover from the right cowl side inner panel. Power Amplifier Connections Remove/Install 3. Disconnect the two instrument panel wire harness connectors from the connector receptacles on the bottom of the power amplifier. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service Precautions > Page 5744 Power Amplifier Remove/Install 4. Remove the two screws that secure the power amplifier to the right cowl side inner panel. 5. To disengage the upper hook bracket of the power amplifier from the upper hinge access hole in the right cowl side inner panel: a. Lift the power amplifier upwards about 5 centimeters (2 inches). b. Tilt the top of the power amplifier toward the instrument panel. c. Keep the top of the power amplifier tilted toward the instrument panel while lowering the unit from between the right cowl side inner panel and the end of the heater-A/C housing. 6. Remove the power amplifier from the right cowl side inner panel. INSTALLATION 1. Position the power amplifier to the right cowl side inner panel. 2. To engage the upper hook bracket of the power amplifier in the upper hinge access hole in the right cowl side inner panel: a. Lift the top of the power amplifier toward the instrument panel. b. Keep the top of the power amplifier tilted toward the instrument panel while lifting the unit up between the right cowl side inner panel and the end of the heater-A/C housing. c. When the lower power amplifier mounting brackets are about 5 centimeters (2 inches) above the mounting holes for the lower brackets in the right cowl side inner panel, tilt the top of the power amplifier toward the right cowl side inner panel. d. Lower the power amplifier until the upper hook bracket is engaged in the upper hinge access hole in the right cowl side inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install and tighten the two screws that secure the power amplifier to the right cowl side inner panel. 4. Reconnect the two instrument panel wire harness connectors to the connector receptacles on the bottom of the power amplifier. 5. Install the trim cover onto the right cowl side inner panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions Radio/Stereo Noise Filter: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 5753 Radio/Stereo Noise Filter: Description and Operation Radio Frequency Interference (RFI) and Electromagnetic Interference (EMI) noise suppression is accomplished primarily through circuitry internal to the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this vehicle to control RFI or EMI noise include the following: - Radio antenna base ground - Radio receiver chassis ground wire or strap - Engine-to-body ground strap(s) - Resistor-type spark plugs - Radio suppression-type secondary ignition wiring. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 5754 Radio/Stereo Noise Filter: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Engine-to-Body Ground Straps Engine-To-Body Ground Strap Remove/Install - Typical 1. Remove the nut and washer that secures the left engine-to-body ground strap eyelet terminal to the weld stud on the left side of the lower plenum panel. 2. Remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard weld stud on the right side of the lower plenum panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service Precautions > Page 5755 Engine-To-Body Ground Strap Remove/Install 3. Remove the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head. 4. Remove the screw that secures the right engine-to-body ground strap eyelet terminal to the rear of the right cylinder head. 5. Remove the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard rear valve cover stud of the right cylinder head. 6. Remove the engine-to-body ground strap(s) from the engine compartment. INSTALLATION Engine-to-Body Ground Straps 1. Position the engine-to-body ground strap(s) in the engine compartment. 2. Position the right engine-to-body ground strap eyelet terminal over the inboard rear valve cover stud of the right cylinder head. 3. Install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet terminal to the inboard rear valve cover stud of the right cylinder head. Tighten the nut to 2.8 Nm (25 in. lbs.). 4. Install and tighten the screw that secures the right engine-to-body ground strap eyelet terminal to the rear of the right cylinder head. On these engines, tighten the screw to 10.2 Nm (90 in. lbs.). 5. Install and tighten the screw that secures the left engine-to-body ground strap eyelet terminal to the rear of the left cylinder head. On these engines, tighten the screw to 10.2 Nm (90 in. lbs.). 6. Position the right engine-to-body ground strap eyelet over the inboard weld stud on the right side of the lower plenum panel. 7. Install and tighten the nut and washer that secures the right engine-to-body ground strap eyelet to the inboard weld stud on the right side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). 8. Install and tighten the nut and washer that secures the left engine-to-body ground strap eyelet to the weld stud on the left side of the lower plenum panel. Tighten the nut to 9 Nm (80 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5764 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5770 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5771 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5772 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Remote Radio Switch Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5773 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remote Radio Switches Remote Radio Switch Test 1. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5774 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover, 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. 5. Install the driver side airbag module onto the steering wheel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Speaker: Specifications Front Door Upper Speaker to Trim Panel Screws 2 Nm Front Door Lower Speaker to Front Door Inner Panel Screws 2 Nm Rear Door Speaker to Rear Door Inner Panel 2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Technician Safety Information Speaker: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Technician Safety Information > Page 5780 Speaker: Vehicle Damage Warnings CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Page 5781 Speaker: Description and Operation Standard The standard equipment speaker system includes speakers in four locations. One full-range 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one full-range 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. Each of the four full-range speakers used in the standard speaker system is driven by the amplifier that is integral to the factory-installed radio receiver. Premium The optional premium speaker system features eight Infinity model speakers in six locations. Each of the standard speakers in the front doors is replaced with Infinity model speakers, and an additional 6.9 centimeter (2.75 inch) diameter Infinity dome tweeter is mounted high in the front door trim panels. The standard speakers in the rear doors are each replaced with an Infinity 16.5 centimeter (6.5 inch) diameter coaxial unit. The premium speaker system also includes an additional Infinity power amplifier. The total available power of the premium speaker system is about 100 watts. The eight Infinity speakers used in the premium speaker system are all driven by the radio receiver through an Infinity power amplifier. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Page 5782 Speaker: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. Turn the ignition switch to the ON position. Turn the radio receiver on. Adjust the balance and fader controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 2. 2. Turn the radio receiver OFF. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the radio receiver from the instrument panel. If the vehicle is equipped with the Infinity speaker package, also disconnect the wire harness connectors at the power amplifier. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker location(s) at the radio receiver wire harness connectors for continuity to ground. In each case, there should be no continuity. If OK, go to Step 3. If not OK, repair the shorted speaker feed (+) and/or return (-) circuit(s) to the speaker as required. 3. If the vehicle is equipped with the Infinity speaker package, go to Step 6. If the vehicle is equipped with the standard speaker system, check the resistance between the speaker feed (+) circuit and return (-) circuit cavities of the radio receiver wire harness connectors for the inoperative speaker location(s). The meter should read between 2 and 28 ohms (speaker resistance). If OK, go to Step 4. If not OK, go to Step 5. 4. Install a known good radio receiver. Connect the battery negative cable. Turn the ignition switch to the ON position. Turn on the radio receiver and test the speaker operation. If OK, replace the faulty radio receiver. If not OK, turn the radio receiver OFF, turn the ignition switch to the OFF position, disconnect and isolate the battery negative cable, remove the test radio receiver, and go to Step 5. 5. Disconnect the wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. 6. For each inoperative speaker location, check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connectors and the power amplifier wire harness connectors. Repeat the check for each inoperative speaker location between the speaker return (-) circuit cavities of the radio receiver wire harness connectors and the power amplifier wire harness connectors. In each case, there should be continuity. If OK, go to Step 7. If not OK, repair the open speaker feed (+) and/or return (-) circuit(s) as required. 7. Check for continuity between the two ground circuit cavities of the power amplifier wire harness connector and a good ground. There should be continuity. If OK, go to Step 8. If not OK, repair the open ground circuit(s) to ground as required. 8. Check the power amplifier fuse in the junction block. If OK, go to Step 9. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 9. Install the radio receiver. Connect the battery negative cable. Check for battery voltage at the power amplifier fuse in the junction block. If OK, go to Step 10. If not OK, repair the open fused B(+) circuit to the PDC as required. 10. Check for battery voltage at the two fused B(+) circuit cavities of the power amplifier wire harness connector. If OK, go to Step 11. If not OK, repair the open fused B(+) circuit(s) to the fuse in the junction block as required. 11. Turn the ignition switch to the ON position. Turn the radio receiver ON. Check for battery voltage at the radio 12 volt output circuit cavity of the power amplifier wire harness connector. If OK, go to Step 12. If not OK, repair the open radio 12 volt output circuit to the radio receiver as required. 12. Turn the radio receiver OFF. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. For each inoperative speaker location, check both the amplified feed (+) circuit and the amplified return (-) circuit cavities of the power amplifier wire harness connectors for continuity to ground. In each case there should be no continuity. If OK, go to Step 13. If not OK, repair the shorted amplified feed (+) and/or amplified return (-) circuit(s) to the speaker as required. 13. For each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) circuit cavities of the power amplifier wire harness connectors. The meter should read between 2 and 28 ohms (speaker resistance). If OK, replace the faulty power amplifier. If not OK, go to Step 14. 14. Disconnect the speaker wire harness connector at the inoperative speaker. Check for continuity between the amplified feed (+) circuit cavities of the speaker wire harness connector and the power amplifier wire harness connector. Repeat the check between the amplified return (-) circuit cavities of the speaker wire harness connector and the power amplifier wire harness connector. In each case there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open amplified feed (+) and/or amplified return (-) circuit(s) as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Page 5783 Speaker: Service and Repair REMOVAL Front Door Upper Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Front Door Upper Speaker Remove/Install 3. Disconnect the door wire harness connector from the front door upper speaker wire harness connector. 4. Remove the two screws that secure the front door upper speaker to the back of the trim panel. 5. Remove the front door upper speaker from the trim panel. Front Door Lower Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the front door. Front Door Lower Speaker Remove/Install 3. Remove the three screws that secure the speaker to the front door inner panel. 4. Pull the speaker away from the mounting hole in the front door inner panel far enough to access the wire harness connector. 5. Disconnect the front door wire harness connector from the speaker connector receptacle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Page 5784 6. Remove the speaker from the front door inner panel. Rear Door Speaker 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the rear door. Rear Door Speaker Remove/Install 3. Remove the three screws that secure the speaker to the rear door inner panel. 4. Pull the speaker away from the mounting hole in the rear door inner panel far enough to access the wire harness connector. 5. Disconnect the rear door wire harness connector from the speaker connector receptacle. 6. Remove the speaker from the rear door inner panel. INSTALLATION Front Door Upper Speaker 1. Position the front door upper speaker to the back of the trim panel. 2. Install and tighten the two screws that secure the front door upper speaker to the trim panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reconnect the door wire harness connector to the front door upper speaker wire harness connector. 4. Install the trim panel onto the front door. 5. Reconnect the battery negative cable. Front Door Lower Speaker 1. Inspect the terminals in the speaker connector receptacle and in the door wire harness connector for corrosion. Clean or replace the terminals as required. 2. Push a small amount of grease (Lithium Extreme Pressure - Number 2 Grade or equivalent) into the cavities of the door wire harness connector for the speaker. 3. Position the speaker to the front door inner panel. 4. Reconnect the front door wire harness connector to the speaker connector receptacle. 5. Position the speaker into the mounting hole in the front door inner panel. 6. Install and tighten the three screws that secure the speaker to the front door inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 7. Install the trim panel onto the front door. 8. Reconnect the battery negative cable. Rear Door Speaker 1. Inspect the terminals in the speaker connector receptacle and in the door wire harness connector for corrosion. Clean or replace the terminals as required. 2. Push a small amount of multipurpose grease (Lithium Extreme Pressure - Number 2 Grade or equivalent) into the cavities of the door wire harness connector for the speaker. 3. Position the speaker to the rear door inner panel. 4. Reconnect the rear door wire harness connector to the speaker connector receptacle. 5. Position the speaker into the mounting hole in the rear door inner panel. 6. Install and tighten the three screws that secure the speaker to the rear door inner panel. Tighten the screws to 2 Nm (17 in. lbs.). 7. Install the trim panel onto the rear door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service Precautions > Page 5785 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams Driver Door Arm/Disarm Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations Door Sensor/Switch (For Alarm): Locations The door ajar switch is integral to the door latch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 5793 Door Sensor/Switch (For Alarm): Description and Operation The door ajar switches are integral to the door latches on each door. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open the ground path when a door is closed. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Locations > Page 5794 Door Sensor/Switch (For Alarm): Service and Repair The door ajar switch is integral to the door latch unit. If the door ajar switch is faulty or damaged, the entire door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation DOOR LOCK CYLINDER SWITCH The door lock cylinder switches are mounted to the back of the key lock cylinder inside each front door. They are resistor multiplexed momentary switches that are hard wired between a body ground and the Central Timer Module (CTM) through the front door wire harnesses. These switches are driven by the key lock cylinders and contain three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The door lock cylinder switches cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. The door lock cylinder switches are actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The door lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the front door key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. LIFTGATE LOCK CYLINDER SWITCH The liftgate lock cylinder switch is mounted to the back of the liftgate key lock cylinder inside the liftgate. It is a resistor multiplexed momentary switch that is hard wired between a body ground and the Central Timer Module (CTM) through the liftgate wire harness. This switch is driven by the key lock cylinder and contains three internal resistors. One resistor is used for the neutral switch position, one for the lock position and one for the unlock position. The liftgate lock cylinder switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The liftgate lock cylinder switch is actuated by the key lock cylinder when the key is inserted in the lock cylinder and turned to the lock or unlock positions. The liftgate lock cylinder switch closes a path to ground through one of three internal resistors for the CTM when the liftgate key lock cylinder is in the lock, unlock or neutral positions. The CTM reads the switch status through an internal pull-up, then uses this input and its internal programming to control the proper Vehicle Theft Security System (VTSS) and power lock system outputs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test Lock Cylinder Switch: Testing and Inspection Door Lock Cylinder Switch Test 1. Disconnect the door lock cylinder switch wire harness connector from the door wire harness connector. DOOR LOCK CYLINDER SWITCH 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the door lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the door lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Door Lock Cylinder Switch chart. 3. If a door lock cylinder switch fails any of the resistance tests, replace the faulty switch as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Testing and Inspection > Door Lock Cylinder Switch Test > Page 5800 Lock Cylinder Switch: Testing and Inspection Liftgate Lock Cylinder Switch Test 1. Disconnect the liftgate lock cylinder switch wire harness connector from the liftgate wire harness connector. Liftgate Lock Cylinder Switch 2. Using an ohmmeter, perform the switch resistance checks between the two cavities of the liftgate lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the liftgate lock cylinder to test for the proper resistance values in each of the three switch positions, as shown in the Lift-gate Lock Cylinder Switch chart. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Replacement > Page 5803 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch Replacement REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the liftgate inner panel. Liftgate Lock Cylinder Switch Remove/Install 3. Reach through the access hole in the liftgate inner panel to disengage the switch from the back of the liftgate lock cylinder. 4. Unplug the liftgate lock cylinder switch wire harness connector. 5. Remove the liftgate lock cylinder switch from the liftgate. 6. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Customer Interest for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5812 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Remote Switch: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Remote Switch: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5818 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5819 Remote Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5820 Remote Switch: Description and Operation A remote radio switch option is available on models equipped with the AM/FM/CD/cassette/3-band graphic equalizer (RAZ sales code) radio receiver and the high-line Central Timer Module (CTM). Remote Radio Switch Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left side is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right side is the volume control switch and has volume up, and volume down functions. The two switches are retained in mounting holes located on each side of the rear steering wheel trim cover by four latches that are integral to the switches. The remote radio switches share a common steering wheel wire harness with the vehicle speed control switches. The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring. The remote radio switches are resistor multiplexed units that are hard wired to the high-line CTM through the clockspring. The CTM monitors the status of the remote radio switches and sends the proper switch status messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For more information on the features and control functions for each of the remote radio switches, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5821 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remote Radio Switches Remote Radio Switch Test 1. Remove the remote radio switch(es) from the steering wheel. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Check for continuity between the ground circuit cavity of the remote radio switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted radio control mux circuit as required. 5. Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures to test the CTM and the Chrysler Collision Detection (CCD) data bus. If not OK, repair the open radio control mux circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Page 5822 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag module from the steering wheel. 3. Remove the speed control switch located on the same side of the steering wheel as the remote radio switch that is being serviced. Remote Radio Switches Remove/Install 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover, 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. 5. Install the driver side airbag module onto the steering wheel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation The liftgate ajar switch is integral to the latch on the liftgate. The switch closes a path to ground for the Central Timer Module (CTM) when the liftgate is opened, and opens the ground path when the liftgate is closed. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 5826 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The liftgate ajar switch is integral to the liftgate latch unit. If the liftgate ajar switch is faulty or damaged, the entire liftgate latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove spare tire. 2. Support trailer hitch on a suitable lifting device. Fig. 8 3. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped (Fig. 8). Fig. 9 4. Remove bolts attaching trailer hitch to frame rails and rear crossmember (Fig. 9). 5. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rail and rear crossmember. Tighten bolts to 108 N.m (80 ft.lbs.) torque. 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 5858 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 5859 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 5863 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 5864 Trailer Towing Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Specifications Trip Computer: Specifications Compass Mini-Trip Computer Module to Overhead Console Housing Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Specifications > Page 5892 Trip Computer: Locations The Compass Mini-Trip Computer is located in the overhead console on models equipped with this option. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 Trip Computer: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 Compass Mini Trip Computer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Compass/Mini - Trip Computer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5917 Trip Computer: Description and Operation The Compass Mini-Trip Computer is located in the overhead console on models equipped with this option. The Compass Mini-Trip Computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The Compass Mini-Trip Computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The Compass Mini-Trip Computer provides several electronic functions and features. Some of the functions and features that the Compass Mini-Trip Computer module supports and/or controls, include the following display options: - Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant Fuel Economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance To Empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. - Elapsed Time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank Screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the Compass Mini-Trip Computer module. Data input for all other Compass Mini-Trip Computer functions, including VFD dimming level, is received through CCD data bus messages. The Compass Mini-Trip Computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the Compass Mini-Trip Computer module and the CCD data bus. The Compass Mini-Trip Computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete Compass Mini-Trip Computer module must be replaced. The Compass Mini-Trip Computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the Compass Mini-Trip Computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This Compass Mini-Trip Computer features several functions that can be reset. If both the Step and U.S./ Metric push buttons are depressed at the same time for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the Compass Mini-Trip Computer, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5918 Trip Computer: Testing and Inspection If the problem with the Compass Mini-Trip Computer module is an "OC" or "SC" in the compass/thermometer display, refer to Ambient Temperature Sensor. If the problem with the Compass Mini-Trip Computer module is an inaccurate or scrambled display, refer to Self-Diagnostic Test. If the problem with the Compass Mini-Trip Computer module is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the Chrysler Collision Detection (CCD) data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fused ignition switch output (RUN/START) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (RUN/START) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavities of the roof wire harness connector for the overhead console and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the roof wire harness connector for the overhead console. If OK, refer to Self-Diagnostic Test for further diagnosis of the Compass Mini-Trip Computer module and the CCD data bus. If not OK, repair the open fused ignition switch output (RUN/START) circuit to the junction block fuse as required. Self-Diagnostic Test A self-diagnostic test is used to determine that the Compass Mini-Trip Computer module is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the OFF position, simultaneously depress and hold the Step button and the U.S./Metric button. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons depressed until the Compass Mini-Trip Computer module enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the Compass Mini-Trip Computer module performs the following checks: a. Microprocessor compass circuit test b. Non-volatile memory read/write test c. Microprocessor ROM verification test d. CCD communications test. 4. Following completion of these tests, the Compass Mini-Trip Computer will return to normal operation or display one of two messages: "FML" or Respond to these test results as follows: a. If no test result message is displayed, but Compass Mini-Trip Computer operation is still improper, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. b. If the "FML" message is displayed, the compass mini4rip computer module is faulty and must be replaced. c. If the "CCD" message is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. d. If any VFD segment should fail to light during the display segment test, the Compass Mini-Trip Computer module is faulty and must be replaced. 5. If all tests are passed, or if the ignition switch is turned to the OFF position, the Compass Mini-Trip Computer module will automatically return to normal operation. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 5919 Trip Computer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Compass Mini-Trip Computer Remove/Install 3. Remove the four screws that secure the Compass Mini-Trip Computer module to the overhead console housing. 4. Pull the Compass Mini-Trip Computer module away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the Compass Mini-Trip Computer module housing by pushing the connector firmly toward the left side of the overhead console housing. 6. Disconnect the overhead console wire harness connector from the Compass Mini-Trip Computer module connector receptacle. 7. Remove the Compass Mini-Trip Computer module from the overhead console housing. INSTALLATION 1. Position the Compass Mini-Trip Computer module onto the overhead console housing. 2. Reconnect the overhead console wire harness connector to the Compass Mini-Trip Computer module connector receptacle. 3. Engage the overhead console wire harness connector onto the mount on the Compass Mini-Trip Computer module housing by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 4. Install and tighten the four screws that secure the Compass Mini-Trip Computer module to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the overhead console onto the headliner. 6. Reconnect the battery negative cable. NOTE: If a new Compass Mini-Trip Computer has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5930 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Central Timer Module: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Central Timer Module: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 5936 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 5937 Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 Central Timer Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Central Timer Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 5985 Central Timer Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation Central Timer Module: Description and Operation System Description and Functional Operation For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2000 DN consists of five modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface of SCI, the same as previous years. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in Vehicle Communication (CCD Bus) of this general information. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTCs) to the technician through the DRBIII (R) via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" or "start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes OFF, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: warning lamp does not illuminate - warning lamp stays illuminated WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. CENTRAL TIMER MODULE The Durango (DN) utilizes a Central Timer Module (CTM). This system is available in a Base or Highline configuration. The Base CTM does not communicate on the CCD bus. The CTM performs most of the typical functions a Body Control Module would perform. The Highline CTM provides the following features: Central Locking Feature - Chime - Courtesy Lamp controls/Illuminated Entry - Power Door Locks - Speed Sensitive Intermittent Wipers - Enhanced Accident Response - Remote Radio Switches - Remote Keyless Entry (RKE) - Vehicle Theft Security System (VTSS) Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5988 The module is located on the right side of the glove box behind a metal bracket. It contains a white 18-way and a green 14-way connector. Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for seat belt, gauge problems and tell-tale warnings. There are two chime rates, Low; 50 ± 12 chimes per minute for reminders and High; 180 ± 12 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left ON. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for approximately six seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: Ignition OFF, key in ignition, driver's door open - Ignition OFF, headlamps ON, driver's door open - Seat belt warning - Malfunction Indicator Lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel warning lamp illuminated - Low washer fluid - Door ajar Compass Mini-Trip Computer (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) - Shows the distance traveled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be traveled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini- trip computer displays. US/M Button Press this button to convert all vehicle displays from US to Metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all reset table conditions will be reset. This will occur only if a resettable function (AVG ECO, Trip Odometer, ET) is currently being displayed. Automatic Compass Calibration This compass is self calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360 turns in an area free from large metal or metallic objects, the CAL symbol will turn OFF and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. To set the variance: Turn the ignition ON and set display to Comp./Temp. While pressing the US/M button, press the STEP button for approximately five seconds. The "VAR" symbol will light and the last variance zone number will be displayed. Press the US/Metric Button to select the proper variance zone as shown on the map. Press the Step button to set the new variance zone and resume normal operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5989 Enhanced Accident Response (Highline CTM Only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "OFF" position, normal operation will resume. Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door key cylinder switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "ON" condition or the "lock" command from a valid key fob. If a door is left open or turned on by rotation of dimmer switch for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by courtesy lamp switch, the CTM will not be able to turn them OFF. The Durango utilizes an interior light defeat switch as an integral part of the headlamp switch. Mechanical Instrument Cluster (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a highline and a low line cluster available. The difference is the addition of a tachometer in the highline. In order to accomplish this, the fuel level gauge is reduced in size and oil pressure gauge is relocated. The cluster positions its gauges with bus messages received from the PCM. The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal diagnostic routing that can be accessed by pushing and holding the trip odometer while rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. The MIC can verify communications with the PCM, ID the module, or change the country code by using options 1, 3, or 9 on the DRBIII (R) under the MIC menu. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off, the door is open, and the key is in the ignition. Automatic or "rolling locks" are included as a DRBIII (R), or customer programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators to lock the doors. RKE/VTSS If the vehicle is equipped with Remote Keyless Entry (RKE), programming of additional transmitters and horn chirp are customer programmable features. The highline CTM provides for RKE and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle is equipped with a highline CTM. The VTSS system monitors the door ajar switches, liftgate (DN) and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRBIII (R). The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in the lift gate or either door. Both front door key cylinders and the liftgate are equipped with key cylinder mux switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB, or by using the customer programming sequence. The system will store up to four key fob codes. Two fobs are supplied with the truck, additional fobs may be purchased through parts department. The additional fobs can be programmed with the DRBIII (R), or by using the customer programming sequence. Through the DRBIII (R), erasing and programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Speed Sensitive Intermittent Wipers The DN truck equipped with a highline CTM will utilize speed sensitive intermittent wipers. Only a highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. Diagnostics Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5990 The CTM is fully addressable with the DRBIII (R) and it is the recommended method for diagnosis. The CTM reports up to 7 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems may use more than one. Some modules are capable of both biasing and terminating. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the PCM and the instrument cluster. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRBIII (R). Problems with the operation of the bus or DRB III (R) must corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications. Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Or open ground to any CCD bus module. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+) and Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with the Instrument Cluster. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII (R). The procedure begins with AIRBAG TEST 1A-Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5991 corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum for 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If the malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal - Logic Capacitor Low - AECM Output Driver Circuit Open - Firing Capacitor Low - Safing Sensor Shorted - Warning Lamp Driver Error For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - Driver Squib Circuit Shorted - Driver Squib Shorted to Battery - Driver Squib Shorted to Ground - Loss of Ignition Run Only - Loss of Ignition Run/Start - No CCD Communication - Passenger Squib Circuit Open - Passenger Squib Circuit Shorted - Passenger Squib Shorted to Battery - Passenger Squib Shorted to Ground - Warning Lamp Circuit Open/Shorted - No Cluster CCD Message - Cluster Message Mismatch Central Timer Module Diagnostic Trouble Codes Key Cylinder Lock Switch Failure/Lock - Door Lock Switch Failure - Door Unlock Switch Failure - Key Cylinder Lock Switch Failure/Unlock - Wiper Park Switch Failure - EEPROM Checksum Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5992 - Internal ROM Test Failure Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5993 Central Timer Module: Description and Operation Central Timer Module For additional information on the Base CTM refer to Instrument Panel, Gauges and Warning Indicators / Audible Warning Device. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > System Description and Functional Operation > Page 5994 These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Central Timer Module: Symptom Related Diagnostic Procedures "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5997 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Chime Inoperative At All Times Test 1 SYMPTOM CHIME INOPERATIVE AT ALL TIMES POSSIBLE CAUSES - CTM-CHIME inoperative Chime Inoperative With Any Lamp or Gauge Warning Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5998 Test 1 - 3 SYMPTOM CHIME INOPERATIVE WITH ANY LAMP OR GAUGE WARNING POSSIBLE CAUSES - Open tone request signal circuit - Instrument cluster- chime inoperative with any warning lamp - CTM - Tone request signal circuit Chime Inoperative With Exterior Lights On and Drivers Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 5999 Test 1 - 4 SYMPTOM CHIME INOPERATIVE WITH EXTERIOR LAMPS ON, DRIVER DOOR OPEN POSSIBLE CAUSES - DRB check driver door ajar - CTM-CHIME inoperative with headlamp switch - Headlamp switch key in ignition switch sense circuit open - Headlamp switch - key in ignition switch sense open Chime Inoperative With Key In Ignition and Driver's Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6000 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6001 Test 4 - 8 SYMPTOM CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6002 - Key-in ignition switch sense circuit open Chime Remains On With Ignition On Test 1 - 3 SYMPTOM CHIME REMAINS ON WITH IGNITION ON POSSIBLE CAUSES - Instrument cluster-chime stays ON - Tone request circuit shorted ground - CTM-CHIME stays ON Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6003 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER'S DOOR OPEN, KEY REMOVED POSSIBLE CAUSES - Key-in IGN switch sense circuit shorted ground - Shorted key-in switch - Headlamp switch shorted test, for chime system Doors Lock With Key In Ignition & Front Door Open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6004 Test 1 - 3 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6005 Test 4 - 8 SYMPTOM DOORS LOCK WITH KEY IN IGNITION & FRONT DOOR OPEN TEST NOTE This symptom is diagnosed using the test CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER'S DOOR OPEN. POSSIBLE CAUSES - Central timer module - Driver door ajar switch sense circuit open - Driver door ajar switch ground circuit open - Driver door ajar switch open - Central timer module - Key-in ignition switch ground circuit open - Key-in ignition switch open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6006 - Key-in ignition switch sense circuit open Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6007 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6008 Central Timer Module: Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6009 Down or Page Up function to display the information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6010 Central Timer Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6011 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Page 6012 Central Timer Module: Tools and Equipment DRBIII (R) (Diagnostic Read-out Box) Jumper Wires Ohmmeter Voltmeter Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair Auxiliary Step / Running Board: Service and Repair RUNNING BOARD REMOVAL NOTE: The running boards can be removed and installed on the vehicle as an assembly. 1. Remove the fasteners from the wheel opening molding. 2. Remove the fasteners retaining the running board brackets to the body. 3. Separate the running boards from the vehicle. INSTALLATI0N 1. Position the running boards on the vehicle. 2. Install the bolts retaining the running board brackets to the body. 3. Install the fasteners in the wheel opening molding. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair FRONT INNER BRACKET REMOVAL 1. Remove bolts attaching top of bumper to bumper bracket. Fig. 1 2. Remove nuts attaching inner bumper bracket to frame (Fig. 1). 3. Using a shallow socket and extension or equivalent, tap with a hammer to drive inner bumper bracket studs out of frame. 4. Separate inner bumper bracket from frame. INSTALLATI0N 1. Position inner bumper bracket studs into frame. 2. Install nuts attaching inner bumper bracket to frame and tighten to 94 N.m (70 ft.lbs.). 3. Install bolts attaching top of bumper to bumper bracket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL 1. Remove the front bumper. 2. Remove the bolts attaching the fascia to the bumper. 3. Separate fascia from bumper. INSTALLATI0N 1. Position fascia on bumper. 2. Install the bolts attaching the fascia to the bumper. 3. Install the front bumper. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR FASCIA REMOVAL 1. Remove rivets at each side rear wheel well. NOTE: Removing the step pad will damage the step pad retainers, verify availability of step pad from parts supplier. 2. Using a trim stick C-4755 or equivalent, carefully pry step pad from fascia. 3. Disconnect license plate lamp connector. Fig. 3 4. Remove upper push pin from the bumper fascia (Fig. 3). 5. Remove the lower push pins from the bumper fascia. 6. Remove the bumper fascia from the bumper (Fig. 2). INSTALLATION 1. Position the bumper fascia on the bumper (Fig. 2). 2. Install upper push pin. 3. Align all holes and install the lower push pins. 4. Position step pad on fascia and press into place. 5. Connect license plate lamp connector. 6. Align fascia bracket, wheel house liner shield and fascia holes and install rivets. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to door handle. 3. Roll glass up. Fig. 3 4. Remove fastener access plug from door end panel (Fig. 3). Fig. 4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 6039 5. Disengage lock cylinder to latch rod from the latch, if equipped. (Fig. 4) 6. Disengage outside handle to latch rod from the latch. 7. Remove nuts attaching outside door handle to door. 8. Separate outside handle from the door. INSTALLATI0N 1. Position outside handle in the door. 2. Install nuts attaching outside door handle to door and tighten to 5.0 N.m (45 in. lbs). 3. Engage outside handle to latch rod to the latch. 4. Engage lock cylinder to latch rod to the latch, if equipped. 5. Install fastener access plug in the door end panel. 6. Install water dam. 7. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair HINGE REMOVAL 1. Support door on a suitable lifting device. 2. Using a grease pencil or equivalent, mark the outline of the door hinge on the hinge pillar and door end frame to aid installation. 3. Remove bolts attaching hinge to door. 4. Remove bolts attaching door hinge to hinge pillar. 5. Separate door hinge from vehicle. INSTALLATION 1. If necessary, paint replacement door hinge before installation. 2. Position door hinge on hinge pillar using alignment marks. 3. Install bolts attaching door hinge to hinge pillar and tighten to 28 N.m (21 ft.lbs.). 4. Install bolts attaching hinge to door and tighten to 28 N.m (21 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS ADJUSTMENT Fig. 7 1. Locate access hole (Fig. 7). 2. Insert a 5/32 inch hex-wrench through hole and into adjustment screw. Loosen screw. 3. Operate outside handle button several times to release any restriction because of misalignment. 4. Tighten adjustment screw to 3 N.m (30 in.lbs.). 5. Test handle button and lock cylinder for proper operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6046 Front Door Latch: Service and Repair LATCH REMOVAL 1. Remove door trim panel. 2. Peel back water dam as necessary. 3. For access to latch, roll up glass and remove bolts attaching rearward glass run channel to door. Move and secure glass run channel. Fig. 6 4. Remove screws attaching latch to door shut face (Fig. 6). 5. Disengage wire harness connector for power door locks, if equipped. 6. Disengage lock button to latch rod from the latch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 6047 Fig. 4 7. Disengage lock cylinder to latch rod from the latch (Fig. 4). 8. Disengage inside handle to latch rod from the latch. 9. Disengage outside handle to latch rod from the latch. 10. Separate latch from door. INSTALLATI0N 1. Engage latch rod to outside handle. 2. Engage inside handle to latch rod to the latch. 3. Engage lock cylinder to latch rod to the latch. 4. Engage lock button to latch rod to the latch. 5. Position latch in door. 6. Install screws attaching latch to door shut face and tighten 9.6 N.m (85 in.lbs.). 7. Engage outside handle to latch rod to the latch. 8. Engage wire harness connector for power door locks, if equipped. 9. Install rearward glass run channel. 10. Install water dam. 11. Install door trim panel. 12. Using the access hole in the door shut face, loosen the latch adjustment screw and ensure the outside door handle is flush with door outer panel. Tighten the adjustment screw. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Front Door Panel: Service and Repair Front Door Trim Panel FRONT DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig.19 Door Trim Panel Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6052 Fig. 22 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6053 Fig. 24 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. 8. Disengage power mirror wire connector, if equipped (driver's side only). Fig. 25 Power Door Lock/Window Connector 9. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 10. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6054 Front Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Roll window down. Fig. 10 2. Remove window crank (Fig. 10), if equipped. Fig. 11 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6055 Fig. 12 3. Remove screws attaching trim panel to door (Fig. 11) and (Fig. 12). CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 13 4. Simultaneously lift upward and outward to release retainer steps from inner door panel (Fig. 13). 5. Disengage inside handle linkage rod from inside handle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6056 Fig. 14 6. Disconnect speaker harness wire connector (Fig. 14). 7. Disengage power mirror wire connector, if equipped (driver's side only) (Fig. 14). Fig. 15 8. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped (Fig. 15). 9. Separate door trim panel from vehicle. INSTALLATI0N 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 6057 Front Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove the trim panel from the door. Fig. 16 2. Carefully separate the waterdam from the door inner panel at the areas with adhesive (Fig. 16). Remove the waterdam from the door inner panel. INSTALLATI0N 1. Apply an appropriate adhesive/sealant to the waterdam edges before installing it. 2. Position the waterdam on the door inner panel and press it inward at the areas with the adhesive to attach it to the inner panel. 3. Ensure that the retainer step pockets are position correctly in the door inner panel. 4. Install the door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Use a wax crayon or equivalent and mark position of striker on B-pillar. Fig. 8 2. Remove bolts attaching striker and shim to B-pillar (Fig. 8). 3. Separate striker from B-pillar. INSTALLATION 1. Using alignment marks, position shim and striker on B-Pillar. 2. Install the bolts tighten to 28 N.m (20 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal Front Door Weatherstrip: Service and Repair Front Door Secondary Seal FRONT DOOR SECONDARY SEAL REMOVAL 1. Remove the push-in fasteners attaching the secondary seal to the inner door panel. 2. Separate the secondary seal from the inner door panel. INSTALLATION 1. Position the secondary seal on the inner door panel. 2. Install the push-in fasteners attaching the secondary seal to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6065 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip FRONT DOOR WEATHERSTRIP REMOVAL 1. Remove A-pillar trim. Refer to Trim Panel. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. Fig. 3 5. Pull weatherstrip from pinch flange around door opening (Fig. 3). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Press B-pillar trim into place. 4. Install lower cowl trim. 5. Install door sill trim. 6. Install A-pillar trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6066 Front Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6067 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6073 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6074 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6075 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 38 Front Door Window Regulator Fig. 39 Power Regulator Bolts 7. Remove screws attaching window regulator to door inner panel. 8. Remove window regulator from door. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6080 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator to door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6081 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 17 Fig. 18 7. Remove screws attaching window regulator to door inner panel (Fig. 17) and (Fig. 18). 8. Remove window regulator from door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 6082 INSTALLATI0N 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove trim panel. 2. Peel back waterdam to access outside handle. 3. Remove glass run channel. Refer to Window Track. Fig. 2 4. Disconnect latch rod (Fig. 2). Fig. 3 5. Remove nuts attaching handle to outer door panel (Fig. 3). 6. Separate outside handle from rear door. INSTALLATION 1. Position outside handle in rear door. 2. Install nuts attaching handle to outer door panel (Fig. 3). 3. Connect latch rod (Fig. 2). 4. Install glass run channel. Refer to Window Track. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 6088 5. Install waterdam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair HINGE REMOVAL 1. Remove B-pillar trim. Refer to Trim Panel. 2. Disconnect door wire harness connector. 3. Support door on suitable stand. 4. Using a grease pencil or equivalent, mark hinge position on B-pillar. Fig. 1 5. Remove bolts attaching hinge to B-pillar (Fig. 1). 6. Separate door from vehicle. 7. Using a grease pencil or equivalent, mark hinge position on door. 8. Remove bolts attaching hinge to door. INSTALLATION 1. Align and position hinge on door. 2. Install bolts attaching hinge to door and tighten to 28 N.m (20 ft.lbs.). 3. Align and position door on vehicle. 4. Install bolts attaching hinge to B-pillar (Fig. 1) and tighten to 28 N.m (20 ft.lbs.). 5. Connect door wire harness connector. 6. Install B-pillar trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair LATCH REMOVAL 1. Remove trim panel. 2. Peel waterdam back to access latch. Fig. 5 3. Disconnect latch rods from latch (Fig. 5). 4. Disconnect the latch harness connector. Fig. 6 5. Remove screws attaching latch to rear door (Fig. 6). INSTALLATION 1. Connect the latch harness connector. 2. Install screws attaching latch to rear door. 3. Connect latch rods to latch. 4. Install waterdam. 5. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel Rear Door Panel: Service and Repair Rear Door Trim Panel REAR DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Fig. 40 Rear Door Trim Panel 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6099 Fig. 10 Trim Panel Retainer 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Fig. 42 Power Window/Lock Connector 7. Disconnect power window/lock harness connector, if equipped. 8. Separate door trim panel from vehicle. 9. If necessary, pull upper trim extension outward to disengage from rear door. INSTALLATION 1. If removed, install upper trim extension on rear door. 2. Position trim panel at door. 3. Engage harness connector for power window/lock, if equipped. 4. Engage inside handle linkage rod to inside handle. 5. Align trim panel retainer steps with inner door panel and slide trim panel into place. 6. Install screws attaching trim panel to door. 7. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6100 Rear Door Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Roll window down. Fig. 8 2. Remove window crank (Fig. 8), if equipped. Fig. 9 3. Remove screws attaching trim panel to door (Fig. 9). CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6101 Fig. 10 4. Simultaneously lift upward and outward to release retainer steps from inner door panel (Fig. 10). 5. Disengage inside handle linkage rod from inside handle. Fig. 11 6. Disconnect power window/lock harness connector, if equipped (Fig. 11). 7. Separate door trim panel from vehicle. 8. If necessary, pull upper trim extension outward to disengage from rear door. INSTALLATI0N 1. If removed, install upper trim extension on rear door. 2. Position trim panel at door. 3. Engage harness connector for power window/lock, if equipped. 4. Engage inside handle linkage rod to inside handle. 5. Align trim panel retainer steps with inner door panel and slide trim panel into place. 6. Install screws attaching trim panel to door. 7. Install window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel > Page 6102 Rear Door Panel: Service and Repair Waterdam WATERDAM REMOVAL 1. Remove door trim panel. 2. Peel the waterdam from the door. 3. Route the latch rods and wire harnesses through the waterdam. Fig. 12 4. Separate the waterdam from the door inner panel (Fig. 12). INSTALLATI0N 1. Route the latch rods and wire harnesses through the waterdam. 2. Position the waterdam on the door, apply adhesive as necessary and press into place. 3. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark position of striker on C-pillar. Fig. 7 2. Remove bolts attaching striker and shim to C-pillar (Fig. 7). 3. Separate striker from C-pillar. INSTALLATION 1. Using alignment marks, position shim and striker on C-Pillar. 2. Install bolts and tighten to 28 N.m (20 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal Rear Door Weatherstrip: Service and Repair C-Pillar Seal C-PILLAR SEAL REMOVAL-C-PILLAR SEAL NOTE: The seal is attached to the door with adhesive tape. Fig. 11 1. Peel the seal from the door (Fig. 11). INSTALLATION-C-PILLAR SEAL 1. Clean the contact area with Mopar(R) Super Kleen or equivalent. 2. Remove the carrier for the seal 3. Align the seal on the door and press into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6110 Rear Door Weatherstrip: Service and Repair Rear Door Secondary Weatherstrip REAR DOOR SECONDARY WEATHERSTRIP REMOVAL Fig. 7 1. Separate the secondary seal from the inner door panel (Fig. 7). INSTALLATION 1. Thoroughly clean the area of old adhesive. Use Mopar(R) Super Kleen or equivalent. 2. Position the secondary seal on the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6111 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip REAR DOOR WEATHERSTRIP REMOVAL 1. Remove door sill trim. 2. Loosen upper and lower B-pillar trim to access weatherstrip. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Pull quarter panel trim outward to access weatherstrip. Fig. 8 5. Pull weatherstrip from pinch flange around door opening (Fig. 8). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Reposition quarter panel trim. 4. Install C-pillar trim. 5. Reposition B-pillar trim. 6. Install door sill trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6112 Rear Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6113 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6119 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6120 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6121 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 55 Rear Door Window Regulator - Manual Fig. 56 Rear Door Window Regulator - Power 8. Remove screws attaching window regulator to door inner panel. 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6126 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6127 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 13 Fig. 14 8. Remove screws attaching window regulator to door inner panel (Fig. 13) and (Fig. 14). 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 6128 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door. Fig. 6 2. Remove the screws attaching the door to the quarter panel (Fig. 6). 3. Remove the door from the panel. INSTALLATION 1. Position the fuel filler door on the quarter panel with the screw holes aligned. 2. Install the screws attaching the fuel filler door to the quarter panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE REMOVAL 1. Open hood and support the side that requires hinge replacement. 2. Remove cowl grille. 3. Mark all bolt and hinge attachment locations using a grease pencil or equivalent, to provide reference marks for installation. Fig. 1 4. Remove the nuts attaching the hinge to the hood (Fig. 1). 5. Remove the bolts attaching the hinge to the inner fender. 6. Separate hinge from vehicle. INSTALLATION 1. If necessary, paint new hinge before installation. 2. Position the hinge on the vehicle and align all marks. 3. Install the bolts attaching the hinge to the inner fender and tighten the bolts to 28.2 N.m (250 in.lbs.). 4. Install the nuts attaching the hinge to the hood and tighten the nuts to 22.6 N.m (200 in.lbs). 5. Install cowl grille. 6. Remove support and verify hood operation. The hood should be aligned to 5 mm (0.2 in.) gap to the front fenders. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair SILENCER PAD REMOVAL Fig. 8 1. Open the hood and remove the retainers attaching the silencer pad to the hood (Fig. 8). 2. Remove the silencer pad from the hood. INSTALLATI0N 1. Position the silencer pad on the hood. 2. Install the retainers attaching the silencer pad to the hood. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments Hood Latch: Adjustments ADJUSTMENTS 1. Open the hood. 2. Loosen the hood latch screws. 3. Move the latch to the correct location and lightly tighten the screws. 4. Close the hood slowly and observe the latching operation. 5. As necessary, adjust the latch position and tighten the screws. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch LATCH REMOVAL 1. Open the hood and using a grease pencil or equivalent, mark latch position for installation alignment. Fig. 4 2. Remove bolts attaching hood latch to radiator closure panel crossmember (Fig. 4). 3. Separate hood latch from crossmember. Fig. 5 4. Disconnect release cable from hood latch (Fig. 5). INSTALLATION 1. Connect release cable to hood latch. 2. Position hood latch on crossmember. Ensure the bottom flange of hood latch (Fig. 5) is secured around the latch bracket (Fig. 4). 3. Install the bolts attaching hood latch to radiator closure panel crossmember and tighten to 10.7 N.m (80 in.lbs.). 4. Close hood and adjust latch as necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 6144 Hood Latch: Service and Repair Safety Latch SAFETY LATCH REMOVAL Fig. 7 1. Open the hood and remove bolts attaching hood safety latch to hood (Fig. 7). 2. Separate safety latch from hood. INSTALLATION 1. Position safety latch on hood. 2. Install bolts attaching safety latch to hood and tighten to 9.6 N.m (85 in.lbs.). 3. Close hood and verify operation. Adjust as necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair INSIDE HOOD RELEASE BRACKET WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Fig. 10 3. Remove the two screws that secure the inside hood release handle to the inside hood release bracket and lower the release handle to the floor (Fig. 10). 4. Depress the latch tabs that secure the 16-way data link connector to the inside hood release bracket, and push the connector out of its mounting hole. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Page 6148 Fig. 11 5. Remove the two screws that secure the inside hood release bracket to the instrument panel structural support (Fig. 11). 6. Remove the inside hood release bracket from the instrument panel structural support. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the inside hood release bracket onto the instrument panel structural support (Fig. 11). 2. Install the two screws that secure the inside hood release bracket to the instrument panel structural support. 3. Install the 16-way data link connector into the mounting hole on the inside hood release bracket. 4. Position the inside hood release handle to the instrument panel lower reinforcement. 5. Install the two screws that secure the inside hood release handle to the inside hood release bracket. 6. Install the steering column opening cover onto the instrument panel. 7. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE REMOVAL 1. Remove hood latch. 2. Detach the release cable and the retainer clips in the engine compartment. 3. Separate the release cable grommet from the dash panel hole. Fig. 6 4. From the inside of the vehicle, remove the screws attaching the hood release handle to the bottom of the instrument panel (Fig. 6). 5. Pull/route the hood release cable through the dash panel hole and remove it via the inside of the vehicle. INSTALLATI0N NOTE: If replacement hood latch is also being installed, ensure that it is thoroughly lubricated. 1. From inside the vehicle, pull/route the hood release cable through the dash panel hole and into the engine compartment. 2. Install the hood release handle. 3. Install the cable grommet in the dash panel hole. 4. Attach the retainer clips to the release cable and install them into the holes in the engine compartment. 5. Attach release cable to hood latch. 6. Install hood latch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Description and Operation Hood Striker: Description and Operation LATCH STRIKER DESCRIPTION The hood latch striker is incorporated with the hood safety latch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Description and Operation > Page 6155 Hood Striker: Adjustments ADJUSTMENTS 1. Open the hood. 2. Loosen the latch striker screws. 3. Slowly close the hood and observe the latching operation. As necessary, adjust the striker position. Tighten the screws. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal Hood Weatherstrip: Service and Repair Hood Seal HOOD SEAL REMOVAL Fig. 2 1. Remove push-in fasteners attaching hood seal to inner hood panel (Fig. 2). 2. Separate hood seal from vehicle. INSTALLATI0N 1. Position hood seal on inner hood panel. 2. Install push-in fasteners attaching hood seal to inner hood panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 6160 Hood Weatherstrip: Service and Repair Cowl Weatherstrip COWL WEATHERSTRIP REMOVAL Fig. 1 1. Grasp cowl seal and pull seal from flange (Fig. 1). 2. Separate cowl seal from vehicle. INSTALLATION 1. Position cowl seal on flange and press into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair BACKLITE REMOVAL 1. Remove liftgate upper trim panel. 2. Remove center high mounted stop lamp. 3. Remove rear window wiper arm, if equipped. 4. Remove side moldings. 5. Cut urethane bonding from around liftgate backlite using a suitable sharp cold knife. A pneumatic cutting device can be used if available. 6. Separate backlite from vehicle. INSTALLATION CAUTION: Open a window before installing backlite. This will avoid pressurizing the passenger compartment. If a door is slammed before urethane is cured, water leaks can result. The window opening fence should be cleaned of old urethane bonding material. 1. Clean inside of backlite with Mopar(R) Glass Cleaner or equivalent and lint-free cloth. 2. Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of backlite. Wipe with clean/dry lint-free cloth. 3. Apply fence primer around edge of fence. Allow at least eighteen minutes drying time. Fig. 8 4. Install new upper and lower seals on liftgate backlite (Fig. 8). 5. Apply a 12 mm (0.4 in.) bead of urethane around window opening fence. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 6165 Fig. 9 6. Position backlite into window opening (Fig. 9). 7. Install the side moldings. 8. Install the rear wiper arm, if equipped. 9. Install the center high mounted stop lamp. 10. Install the liftgate upper trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair HINGE REMOVAL 1. Remove liftgate upper trim. 2. Remove D-pillar trim. Refer to Trim Panel. 3. Support liftgate on a suitable lifting device. 4. Using a wax crayon or equivalent, mark the position of the hinge on the liftgate and roof panel. 5. Remove liftgate support cylinder from liftgate. 6. Remove bolts attaching hinge to liftgate. Fig. 2 7. Carefully pull headliner down and remove bolts attaching liftgate hinge to roof panel (Fig. 2). 8. Remove hinge from vehicle. INSTALLATION 1. If necessary, paint replacement hinge before installation. 2. Position hinge on liftgate. 3. Align hinge to marks on liftgate. 4. Install bolts attaching hinge to liftgate. NOTE: Apply 3M-Drip Check Sealant (or an equivalent product) to hinge bolt threads. 5. Align hinge to marks on roof. 6. Install bolts attaching hinge to roof panel. 7. Install liftgate support cylinder to liftgate. 8. Remove support from liftgate. 9. Install D-pillar trim. 10. Install liftgate upper trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove liftgate trim panels. 2. Disconnect liftgate lamp harness connector. 3. Position aside the liftgate watershield to expose liftgate handle. 4. Disconnect vehicle security harness connector, if equipped. 5. Disconnect latch rod and actuator rod. Fig. 1 6. Remove nuts attaching outside handle to liftgate (Fig. 1). 7. Separate outside handle from liftgate. INSTALLATION 1. Position outside handle on liftgate. 2. Install nuts attaching outside handle to liftgate. 3. Connect latch rod and actuator rod. 4. Connect vehicle security harness connector, if equipped. 5. Install liftgate watershield. 6. Connect liftgate lamp harness connector. 7. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Trim Panel Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Pull upper trim outward to disengage spring clips. 2. Separate upper trim from liftgate. Fig. 10 3. Remove screws attaching lower trim to liftgate (Fig. 10). 4. Pull lower trim outward to disengage spring clips. 5. Disconnect liftgate lamp wire connector. 6. Separate lower trim from liftgate. INSTALLATI0N 1. Position lower trim at liftgate. 2. Connect liftgate lamp wire connector. 3. Align lower trim on liftgate and press inward to engage spring clips. 4. Install screws attaching lower trim to liftgate (Fig. 10). 5. Position upper trim on liftgate. 6. Align upper trim to liftgate and press inward to engage spring clips. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Trim Panel > Page 6176 Trunk / Liftgate Interior Trim Panel: Service and Repair Molding MOLDING REMOVAL Fig. 7 1. Remove screws attaching molding to liftgate (Fig. 7). 2. Separate molding from liftgate. INSTALLATI0N 1. Position molding on liftgate. 2. Install screws attaching molding to liftgate (Fig. 7). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair LATCH REMOVAL 1. Remove liftgate trim panels. 2. Disconnect liftgate lamp harness connector. 3. Peel back liftgate latch watershield. 4. Disconnect liftgate to outside handle latch rod. Fig. 3 5. Remove screws attaching latch to liftgate (Fig. 3). 6. Separate latch from liftgate. INSTALLATI0N 1. Position latch in liftgate. 2. Install screws attaching latch to liftgate (Fig. 3) and tighten to 27.8 N.m (20.5 ft.lbs.). 3. Connect liftgate to outside handle latch rod. 4. Install liftgate latch watershield. 5. Connect liftgate lamp harness connector. 6. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove liftgate trim panels 2. Remove liftgate handle. 3. Remove clip retaining lock cylinder in outside handle. 4. Remove the clip retaining actuator link to lock cylinder. Remove actuator link. Fig. 6 5. Separate lock cylinder from handle (Fig. 6). INSTALLATION 1. Position lock cylinder in outside handle (Fig. 6). 2. Install clip retaining lock cylinder in handle. 3. Install actuator link and retaining clip. 4. Install liftgate handle. 5. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL 1. Support liftgate on a suitable lifting device. Fig. 8 2. Remove bolt attaching liftgate support cylinder to D-pillar (Fig. 8). Fig. 9 3. Remove bolt attaching liftgate support cylinder to liftgate (Fig. 9). 4. Remove liftgate support cylinder from liftgate. INSTALLATION 1. Position liftgate support cylinder on liftgate. 2. Install bolt attaching liftgate support cylinder to liftgate, note top and bottom of support cylinder. 3. Install bolt attaching liftgate support cylinder to D-pillar (Fig. 8) and tighten to 28.2 N.m (250 in.lbs.). 4. Remove lifting device. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair LATCH STRIKER REMOVAL 1. Remove liftgate trim scuff pad. Fig. 4 2. Remove screws attaching liftgate striker to floor pan (Fig. 4). 3. Separate striker from vehicle. INSTALLATION 1. Position striker on vehicle. 2. Install screws attaching liftgate striker to floor pan (Fig. 4) and tighten to 27.8 N.m (20.5 ft.lbs.). 3. Install liftgate trim scuff pad. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair LIFTGATE OPENING WEATHERSTRIP REMOVAL 1. Remove liftgate opening upper trim. 2. Remove liftgate opening scuff plate. Fig. 4 3. Pull weatherstrip from liftgate opening (Fig. 4). INSTALLATION 1. Position weatherstrip in liftgate opening and align corners (Fig. 4). 2. Press weatherstrip onto flange and carefully place over quarter panel trim. 3. Connect ends at bottom/center of liftgate opening. 4. Install liftgate opening scuff plate. 5. Install liftgate opening upper trim. 6. Carefully place weatherstrip over trim using a fiber stick. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES REMOVAL NOTE: Exterior nameplates are attached to body panels with adhesive tape. 1. Apply a length of masking tape on the body, parallel to the top edge of the nameplate to use as a guide, if necessary. 2. If temperature is below 21 degrees C (70 degrees F) warm emblem with a heat lamp or gun. Do not exceed 52 degrees C (120 degrees F) when heating emblem. 3. Insert a plastic trim stick or a hard wood wedge behind the emblem to separate the adhesive backing from the body. 4. Clean adhesive residue from body with MOPAR(R) Super Clean solvent or equivalent. INSTALLATI0N 1. Remove carrier from adhesive tape on back of emblem. Fig. 5 2. Position emblem properly on body (Fig. 5). 3. Press emblem firmly to body with palm of hand. 4. If temperature is below 21 degrees C (70 degrees F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52 degrees C (120 degrees F) when heating emblem. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS REMOVAL 1. Apply a length of masking tape on the body, parallel to the top edge of the molding to use as a guide, if necessary. 2. Warm the effected adhesive type molding and body metal to approximately 38 degrees C (100 degrees F) using a suitable heat lamp or heat gun. Fig. 1 3. Pull stick-on molding from painted surface (Fig. 1). INSTALLATION 1. Clean body surface with MOPAR(R) Super Kleen solvent or equivalent. Wipe surface dry with lint free cloth. 2. Remove protective cover from tape on back of molding. Apply molding to body below the masking tape guide. 3. Remove masking tape guide and firmly press molding to body surface to assure adhesion. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Remove the front wheel. 2. Remove wheel opening molding. Fig. 9 3. Remove plastic rivets attaching wheelhouse liner to wheelhouse (Fig. 9). 4. Separate liner from vehicle. INSTALLATI0N 1. Position liner in wheelhouse. 2. Install plastic rivets attaching wheelhouse liner to wheelhouse. 3. Install wheel opening molding. 4. Install the front wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel. Fig. 11 3. Remove plastic rivets attaching wheelhouse liner to vehicle (Fig. 11). 4. Separate wheelhouse liner from vehicle. INSTALLATION 1. Position wheelhouse liner on vehicle. 2. Align holes and install plastic rivets (Fig. 11). 3. Install the wheel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates Cross-Member: Technical Service Bulletins Engine/Electrical - Torque Spec/Schematic Updates NUMBER: 26-02-00D GROUP: Miscellaneous DATE: April, 2000 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 2000 Durango Service Manual - Publication Number 81-370-0016 DESCRIPTION OF CHANGES Updates to the wiring schematic Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6216 8W-30-25 Updates to the engine support & crossmember torque specifications Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6217 9-29 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6218 9-81 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6219 9-102 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6220 9-132 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6221 9-160 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6222 9-161 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6223 1-189 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Engine/Electrical - Torque Spec/Schematic Updates > Page 6224 Cross-Member: Technical Service Bulletins Transmission Crossmember - Service Precautions NUMBER: 13-002-00 GROUP: Frame And Bumpers DATE: Oct. 27, 2000 SUBJECT: Transmission Crossmember Service MODELS: 2000 - 2001 (AN) Dakota 2000 - 2001 (DN) Durango DISCUSSION: The fasteners that retain the transmission crossmember to the frame utilize a thread lock patch on the threads of the fastener. The thread lock patch is required to help prevent the fastener from loosening during normal vehicle usage. When the transmission crossmember is required to be removed during service, the amount of thread patch material on the fastener will deteriorate during fastener removal. To ensure that the fastener retention is not compromised after service, the transmission crossmember fastener threads must have Mopar Lock & Seal p/n 04318031 added to the threads of each fastener. POLICY: Information Only Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair Skid Plate: Service and Repair FUEL TANK SKID PLATE REMOVAL 1. Position a support under skid plate. 2. Remove inboard screws that attach skid plate to crossmember. Fig. 7 3. Remove bolts that attach skid plate to frame side rail (Fig. 7). 4. Remove support and skid plate from vehicle. INSTALLATION 1. Position and support skid plate under fuel tank. 2. Install inboard screws attaching skid plate to crossmember and tighten to 41 N.m (30 ft.lbs.). 3. Install bolts attaching skid plate to frame side rail and tighten to 23 N.m (17 ft.lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove spare tire. 2. Support trailer hitch on a suitable lifting device. Fig. 8 3. Remove fasteners attaching trailer wiring connector to trailer hitch, if equipped (Fig. 8). Fig. 9 4. Remove bolts attaching trailer hitch to frame rails and rear crossmember (Fig. 9). 5. Separate trailer hitch from vehicle. INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts attaching trailer hitch to frame rail and rear crossmember. Tighten bolts to 108 N.m (80 ft.lbs.) torque. 3. Install fasteners attaching trailer wiring connector to trailer hitch, if equipped. 4. Install spare tire. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 6234 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 6235 Trailer Towing Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair GRILLE REMOVAL 1. Open hood. 2. Remove screws attaching bottom of grille to grille mounting bracket. Fig. 7 3. Remove nuts attaching grille to hood (Fig. 7). 4. Separate grille from vehicle. INSTALLATION 1. Position grille on hood. 2. Install nuts attaching grille to hood. 3. Install screws attaching bottom of grille to grille mounting bracket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Arm Rest: Customer Interest Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 6248 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Arm Rest: All Technical Service Bulletins Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 6254 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Center Seat Armrest / Console Arm Rest: Service and Repair Center Seat Armrest / Console CENTER SEAT ARMREST/CONSOLE REMOVAL CAUTION: Mark bolt head position prior to disassembly. Failure to maintain proper track spacing may result in high track efforts. 1. Remove bucket seats. Fig. 5 2. Remove the bolts attaching the center seat to the bucket seat inboard seat tracks (Fig. 5). 3. Route the seat belt buckles through the elastic retaining straps. 4. Separate the center seat/armrest from the bucket seats. INSTALLATION 1. Position the center seat/armrest onto the bucket seat inboard seat tracks. 2. Route the seat belt buckles through the elastic retaining straps. 3. Install the bolts attaching the center seat to the bucket seat inboard tracks and tighten to 24 N.m (17 ft. lbs.). 4. Install bucket seats. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Center Seat Armrest / Console > Page 6257 Arm Rest: Service and Repair Center Armrest Inertia Latch Cover CENTER ARMREST INERTIA LATCH COVER REMOVAL 1. Move the drivers seat position to full forward with seat back full forward. 2. Place center arm rest in the down position. Fig. 6 3. Remove the screw securing the cover to the inertia latch (Fig. 6). 4. Remove the upper and lower inertia latch covers. INSTALLATION 1. Install the upper latch cover onto the upper latch inertia arm. Ensure the check strap loops under the stud on the side of the lower stanchion/post. 2. Install the lower latch cover onto the inertia latch upper arm working it around the latch bracket. 3. Align the lower latch cover, the upper latch cover, and the latch bracket to the screw hole on the arm. 4. Secure the cover with the screw and tighten to 4 N.m (37 in. lbs.). 5. Cycle the armrest through a full range of travel and check for freedom of movement. Adjust the latch covers as necessary. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Carpet Carpet: Service and Repair Front Carpet FRONT CARPET REMOVAL 1. Remove floor console. 2. Remove front seats. 3. Remove 2nd row seats. 4. Remove 3rd row seats, if equipped. 5. Remove front and rear door sill trim. 6. Remove lower left and right cowl trim. 7. Remove left and right B-pillar trim. Refer to Trim Panel. 8. Remove left and right quarter panel trim. 9. Loosen gas pedal bracket. 10. Remove rear fresh air vent. 11. Route wiring through carpet. Fig. 3 12. Remove carpet from vehicle (Fig. 3). INSTALLATION 1. Position carpet in vehicle and align all holes. 2. Route all wire harnesses through openings in carpet. 3. Install front and rear door sill trim. 4. Install quarter panel trim. 5. Install B-pillar trim. Refer to Trim Panel. 6. Install lower cowl trim. 7. Tighten gas pedal bracket. 8. Install 3rd row seats, if equipped. 9. Install 2nd row seats. 10. Install rear fresh air vent. 11. Install front seats. 12. Install floor console. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Front Carpet > Page 6262 Carpet: Service and Repair Rear Carpet REAR CARPET REMOVAL 1. Remove 3rd row seats, if equipped. 2. Remove 3rd row seat belt/buckles, if equipped. 3. Remove left and right quarter panel trim. 4. Remove liftgate scuff plate. 5. Remove screws attaching cargo compartment lid hinge to floor. Fig. 4 6. Remove carpet from vehicle (Fig. 4). INSTALLATION 1. Position carpet in vehicle and align all holes. 2. Install screws attaching cargo compartment lid hinge to floor. 3. Install liftgate scuff plate. 4. Install quarter panel trim. 5. Install 3rd row seat belt/buckles, if equipped. 6. Install 3rd row seats, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Console: Customer Interest Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 6271 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Console: All Technical Service Bulletins Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 6277 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 6278 Console: Specifications Overhead Console housing to Overhead Console Bracket Screws 1.9 Nm Paper Clip to Overhead Console Housing Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 Console: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6301 Console: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Overhead Console ............................................................................................................................... ...................................................................... 212-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6302 Console: Description and Operation OVERHEAD CONSOLE SYSTEM An overhead console unit is an available factory-installed option on this model. The overhead console unit features a garage door opener storage bin, a sunglasses storage bin, two reading and courtesy lamps and either a standard paperclip or an optional compass mini-trip computer. See the owner's manual in the vehicle glove box for more information on the features, use and operation of all of the overhead console components and systems. OVERHEAD CONSOLE Overhead Console The overhead console for this model includes two front-mounted reading and courtesy lamps, a garage door opener storage bin, a sunglasses storage bin and either a standard paperclip or an optional compass mini-trip computer. The overhead console is secured with two snap clips at the rear and a single screw at the front to the overhead console mounting bracket. The front of the overhead console mounting bracket is secured to the roof header near the windshield with two screws, and the rear of the bracket is secured with double faced tape to the inside surface of the roof panel. A single electrical connection joins the overhead console wire harness to the roof wire harness. Following are general descriptions of the major components used in the overhead console. See the owner's manual in the vehicle glove box for more information on the use and operation of the various overhead console features. COMPASS MINI-TRIP COMPUTER The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6303 - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the compass mini-trip computer module. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CCD data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the CCD data bus. The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. Thermometer The thermometer displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the thermometer display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the OFF position, the last displayed temperature reading stays in the thermometer unit memory. When the ignition switch is turned to the ON position again, the thermometer will display the memory temperature if the engine coolant temperature is above about 52 °C (125 °F). If the engine coolant temperature is below about 52 °C (125 °F), the thermometer will display the actual temperature sensed by the ambient temperature sensor. The thermometer temperature display update interval varies with the vehicle speed. The thermometer function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the module. The ambient temperature sensor is available as a separate service item. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If both the Step and U.S./ Metric push buttons are depressed at the same time for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. OVERHEAD CONSOLE READING AND COURTESY LAMP The overhead console in this vehicle is equipped with two individual reading and courtesy lamps. The lamp lenses are the only visible components of these lamps. The reading and courtesy lamp lenses are mounted in the overhead console housing between the compass mini-trip computer display and the sunglasses storage bin. Each lamp has its own switch, bulb, and lens; but both lamps share a common lamp housing within the overhead console. The overhead console reading and courtesy lamps operate on battery current that is provided at all times, regardless of the ignition switch position. The ground feed for the lamps is switched through the integral reading and courtesy lamp switches or through the door jamb switches. Each lamp is designed and aimed to provide illumination that will be directed only to that side of the vehicle on which the lamp is located. The reading and courtesy lamp lenses, bulbs and the lamp housing are available for service replacement. The reading and courtesy lamp switches, bulb holders and wiring are only available as part of the overhead console wire harness. If either of the lamp switches or bulb holders is faulty or damaged, the entire overhead console wire harness assembly must be replaced. For service of the reading and courtesy lamp bulbs, refer to Overhead Console Reading Lamp Bulbs. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 6304 All reading and courtesy lamps located in the overhead console are activated by the door jamb switches. When all of the doors are closed, these lamps can be individually activated by depressing the corresponding lens. When any door is open, depressing the lamp lenses to activate the lamp switches will not turn the lamps OFF. See the owner's manual in the vehicle glove box for more information on the use and operation of the overhead console reading and courtesy lamps. GARAGE DOOR OPENER STORAGE BIN A compartment near the rear of the overhead console is designed to hold most garage door opener remote control transmitters. The door for the garage door opener compartment features a spring-loaded latch mechanism and has a small depression with tactile ribs just forward of the latch. The transmitter is mounted within the compartment with an adhesive-backed hook and loop fastener patch and, when the compartment is closed, the depressed area of the compartment door is pressed upward to actuate the transmitter. A transmitter mounting kit including the adhesive backed hook and loop fastener material and additional adapter pegs is available for service. The garage door opener storage bin door is also available for service replacement. The door unit includes the spring-loaded latch mechanism. If any of these components is damaged or faulty, the garage door opener storage bin door unit must be replaced. The garage door opener storage compartment door is opened by pressing the spring-loaded latch towards the front of the vehicle. When the compartment door is opened, the garage door opener transmitter can be installed in the compartment using the adhesive-backed hook and loop fastener material provided. With the transmitter mounted in the storage bin, adapter pegs located on the inside of the garage door opener door are selected and mounted on one of several posts on the back side of the door. The adapter pegs can be stacked if additional length is required. The combination of the adapter peg length and the peg location selected must be suitable to depress the button of the transmitter when the center of the garage door opener storage bin door is depressed. When the proper combination has been selected, the compartment door is closed and need not be reopened except to replace the transmitter batteries. See the owner's manual in the vehicle glove box for more information on the use and operation of the overhead console garage door opener storage bin. PAPERCLIP A paperclip is standard equipment on the base version of the overhead console. The paperclip provides a convenient place for storage and easy retrieval of notes, maps, toll tickets or stubs and other paper items that may be required or desired while driving. The paperclip is located near the front of the overhead console and is secured in the overhead console housing by four screws. The paperclip is available for service replacement, but it cannot be adjusted or repaired. If the paperclip is damaged or faulty it must be replaced. SUNGLASSES STORAGE BIN A sunglasses storage bin is included in the overhead console. The storage bin is located near the center of the overhead console and is held in the closed position by a spring-loaded latch mechanism that is integral to the storage bin door. The interior of the bin is lined with a foam rubber padding material to protect the sunglasses from being scratched. A damper spring is snapped onto the pivot shaft of the sunglasses storage bin door. The damper spring engages two flats on the shaft and is anchored in a slot in the rear flange of the overhead console reading and courtesy lamp housing to provide a smooth opening action and an open detent position for the storage bin unit. The sunglasses storage bin and door unit is available for service replacement. The bin and door unit includes the spring-loaded latch mechanism, the bin liner and the damper spring. If any of these components is damaged or faulty, the sunglasses storage bin and door unit must be replaced. The sunglasses storage bin is opened by pressing the latch on the rear edge of the door towards the front of the vehicle, then pulling the bin downward to the open detent position. The spring-loaded latch mechanism on the sunglasses bin door will automatically engage when the bin is closed. See the owner's manual in the vehicle glove box for more information on the use and operation of the sunglasses storage bin. AMBIENT TEMPERATURE SENSOR Ambient air temperature is monitored by the compass mini-trip computer module through the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the compass mini-trip computer module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the compass mini-trip computer module. Based upon the resistance in the sensor, the compass mini-trip computer module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures Console: Procedures Sunglasses Storage Bin Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the reading and courtesy lamp housing from the overhead console. 3. Unlatch and remove the sunglasses storage bin from the overhead console housing. INSTALLATION 1. Position the sunglasses storage bin into the overhead console housing. 2. Engage the latch of the sunglasses storage bin with the latch striker on the rear of the storage bin opening in the overhead console housing. 3. Be certain that the sunglasses storage bin pivot shaft is located in the two pivot receptacles just behind the reading and courtesy lamp lenses in the overhead console housing. 4. Be certain that the sunglasses storage bin damper spring is installed on the pivot shaft with the two end tabs of the spring engaged with the flats on the rear of the shaft, and the center tab engaged over the front of the shaft. 5. Install the reading and courtesy lamp housing onto the overhead console. 6. Reconnect the battery negative cable. Overhead Console Replacement REMOVAL Console 1. Disconnect and isolate the battery negative Overhead Console Remove/Install 2. Remove the screw that secures the front of the overhead console to the front of the overhead console bracket. 3. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing in the area between the garage door opener storage bin and the sunglasses storage bin. 4. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the two snap clips that secure the rear of the unit from their receptacles in the overhead console bracket. 5. Lower the overhead console from the headliner far enough to access the wire harness connector. 6. Disconnect the roof wire harness connector from the overhead console wire harness connector. 7. Remove the overhead console from the headliner. Overhead Console Bracket 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the overhead console bracket. 3. Remove the headliner from the roof panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6307 Overhead Console Bracket Remove/Install 4. Remove the two screws that secure the front of the overhead console bracket to the roof front header. 5. Using a sharp utility knife, cut through the double-faced tape that secures the rear flange of the overhead console bracket to the roof panel. 6. Remove the overhead console bracket from the roof panel. INSTALLATION Overhead Console 1. Position the overhead console near the mounting location on the headliner. 2. Reconnect the roof wire harness connector to the overhead console wire harness connector. 3. Align the locating pin on the rear of the overhead console housing with the receptacle in the rear of the overhead console bracket. 4. Align the two snap clips on the overhead console housing with their receptacles in the overhead console bracket. 5. Push upward firmly and evenly on the sides of the overhead console housing over both of the snap clip locations until each of the two snap clips is fully engaged with its receptacle in the overhead console bracket. 6. Install and tighten the screw that secures the front of the overhead console housing to the overhead console bracket. Tighten the screw to 1.9 Nm (17 in. lbs.). 7. Reconnect the battery negative cable. Overhead Console Bracket 1. Remove any remnants of the old double-faced tape from the roof panel and the rear flange of the overhead console bracket and clean these areas with a suitable solvent to remove any traces of grease, oil or adhesive residue. when installing the overhead console bracket, always apply a new piece of double faced tape to the rear flange of the bracket. 2. Align the two locating pins on the front of the overhead console bracket with the receptacles in the roof front header. 3. Lower the rear flange of the overhead console bracket from the roof panel far enough to access and remove the release paper from the double-faced tape. 4. Push upward firmly and evenly on the rear flange of the overhead console bracket over the double-faced tape to ensure complete adhesion to the roof panel. 5. Install and tighten the two screws that secure the front of the overhead console bracket to the roof front header. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the headliner onto the roof panel. 7. Install the overhead console onto the overhead console bracket. 8. Reconnect the battery negative cable. Paperclip Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. 3. Remove the four screws that secure the paperclip to the overhead console housing. 4. Pull the paperclip away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the paperclip by pushing the connector firmly toward the left side of the overhead console housing. 6. Remove the paperclip from the overhead console housing. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6308 1. Position the paperclip onto the overhead console housing. 2. Engage the overhead console wire harness connector onto the mount on the paperclip by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 3. Install and tighten the four screws that secure the paper clip to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Install the overhead console onto the headliner. 5. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6309 Console: Removal and Replacement Center Seat Armrest / Console CENTER SEAT ARMREST/CONSOLE REMOVAL CAUTION: Mark bolt head position prior to disassembly. Failure to maintain proper track spacing may result in high track efforts. 1. Remove bucket seats. Fig. 5 2. Remove the bolts attaching the center seat to the bucket seat inboard seat tracks (Fig. 5). 3. Route the seat belt buckles through the elastic retaining straps. 4. Separate the center seat/armrest from the bucket seats. INSTALLATION 1. Position the center seat/armrest onto the bucket seat inboard seat tracks. 2. Route the seat belt buckles through the elastic retaining straps. 3. Install the bolts attaching the center seat to the bucket seat inboard tracks and tighten to 24 N.m (17 ft. lbs.). 4. Install bucket seats. Center Armrest Inertia Latch Cover CENTER ARMREST INERTIA LATCH COVER REMOVAL 1. Move the drivers seat position to full forward with seat back full forward. 2. Place center arm rest in the down position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6310 Fig. 6 3. Remove the screw securing the cover to the inertia latch (Fig. 6). 4. Remove the upper and lower inertia latch covers. INSTALLATION 1. Install the upper latch cover onto the upper latch inertia arm. Ensure the check strap loops under the stud on the side of the lower stanchion/post. 2. Install the lower latch cover onto the inertia latch upper arm working it around the latch bracket. 3. Align the lower latch cover, the upper latch cover, and the latch bracket to the screw hole on the arm. 4. Secure the cover with the screw and tighten to 4 N.m (37 in. lbs.). 5. Cycle the armrest through a full range of travel and check for freedom of movement. Adjust the latch covers as necessary. Floor Console FLOOR CONSOLE REMOVAL Fig. 11 1. Using a small flat blade, remove forward and rearward rubber inserts (Fig. 11). 2. Remove bolts attaching floor console to floor pan. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Procedures > Page 6311 3. Disconnect electrical connector. 4. Remove the console. INSTALLATION 1. Connect electrical connector. 2. Position the locator tabs and install the console. 3. Install the seven bolts and tighten to 5 N.m (45 in. lbs.). 4. Install the rubber inserts into the console. Mini Floor Console MINI FLOOR CONSOLE REMOVAL Fig. 12 1. Remove the rubber mats (Fig. 12). 2. Remove the bolts and remove the console. INSTALLATION 1. Position the locator tab and install the console. 2. Install the three bolts and tighten to 5 N.m (45 in. lbs.). 3. Install the rubber console mats. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 6312 Degaussing Tool 6029 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6317 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service Precautions Glove Compartment: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement Glove Compartment: Removal and Replacement Glove Box GLOVE BOX ASSEMBLY REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. 3. Remove the lower bezel from the instrument panel. 4. Remove the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. 5. Remove the passenger side end cap from the instrument panel. 6. Remove the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. Fig. 5 7. Remove the four screws that secure the bottom of the glove box module to the instrument panel (Fig. 5). 8. Unlatch and open the glove box. 9. Remove the latch striker from the upper glove box opening reinforcement. 10. Remove the two remaining screws that secure the top of the glove box module to the upper glove box opening reinforcement. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6323 Fig. 6 11. If the vehicle is equipped with a glove box lamp, pull the glove box module away from the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle (Fig. 6). 12. Remove the glove box module from the instrument panel. DISASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle are serviced individually. The following is the procedure for disassembling this component. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the glove box door from the glove box module. 2. Remove the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. Fig. 7 3. Remove the glove box bin from the inside of the glove box door (Fig. 7). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6324 NOTE: Dakota shown, Durango similar. 4. Remove the two screws that secure the glove box latch and handle to the inside of the glove box door. 5. Remove the glove box latch and handle from the inside of the glove box door. ASSEMBLY The glove box latch and handle unit of the glove box used in this vehicle is serviced individually. Following are the procedures for assembling this component to the glove box module. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box latch and handle to the inside of the glove box door. 2. Install the two screws that secure the glove box latch and handle to the inside of the glove box door. 3. Position the glove box bin to the inside of the glove box door (Fig. 7). 4. Install the nine screws that secure the flanges around the perimeter of the glove box bin to the inside of the glove box door. 5. Install the glove box door. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the glove box module to the instrument panel. 2. If the vehicle is equipped with a glove box lamp, reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle (Fig. 6). 3. Position the top of the glove box module to the upper glove box opening reinforcement. 4. Install the two outboard screws that secure the top of the glove box module to the upper glove box opening reinforcement (Fig. 5). 5. Install the glove box latch striker to the upper glove box opening reinforcement. 6. Close and latch the glove box. 7. Install the four screws that secure the bottom of the glove box module to the instrument panel (Fig. 5). 8. Install the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap. 9. Install the passenger side end cap onto the instrument panel. 10. Install the screw that secures the inboard side of the glove box module to the instrument panel behind the lower bezel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6325 Fig. 8 11. Open and close the glove box to check for proper hinge operation and alignment (Fig. 8). 12. Install the lower bezel onto the instrument panel. 13. Install the cluster bezel onto the instrument panel. 14. Connect the battery negative cable. Glove Box Latch Striker Replacement GLOVE BOX LATCH STRIKER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unlatch and open the glove box. Fig. 9 3. Remove the two screws that secure the latch striker to the upper glove box opening reinforcement (Fig. 9). 4. Remove the latch striker from the upper glove box opening reinforcement. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the latch striker onto the upper glove box opening reinforcement (Fig. 9). 2. Install the two screws that secure the latch striker to the upper glove box opening reinforcement. 3. Close and latch the glove box and check fit. 4. Adjust the striker, if required. 5. Connect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Removal and Replacement > Page 6326 Glove Compartment: Overhaul The only serviced component of the glove box is the glove box bin. If any other component of the glove box is faulty or damaged, the entire glove box assembly must be replaced. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL Glove Box Bin 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Glove Box Components Remove/Install 3. Remove the two screws that secure each outboard flange of the glove box bin to the glove box door. 4. Remove the two remaining screws in the bottom of the glove box bin (the center screw was removed during glove box removal) that secure the bin to the bottom of the glove box door. 5. Remove the four screws that secure the top of the glove box bin and the glove box latch to the glove box door. 6. Remove the glove box bin and the glove box latch from the glove box door. INSTALLATION Glove Box Bin 1. Position the glove box latch and the glove box bin to the glove box door. 2. Install and tighten the four screws that secure the top of the glove box bin and the glove box latch to the glove box door. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install and tighten the two outboard screws in the bottom of the glove box bin (the center screw will be installed following glove box installation) that secure the bin to the bottom of the glove box door. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Install and tighten the two screws that secure each outboard flange of the glove box bin to the glove box door. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the glove box onto the instrument panel 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures HEADLINER REMOVAL (1) Disconnect battery negative cable. (2) Remove sunvisors and sunvisor arm supports. (3) Remove coat hooks. (4) Remove overhead assist handle. (5) Remove dome lamp. (6) Remove overhead console, if equipped. (7) Remove outlet bezel for rear air conditioner, if equipped. (8) Remove blower control switch for rear air conditioner, if equipped. (9) Remove upper liftgate opening trim. (10) Disengage A-pillar, B-pillar, C-pillar, and D-pillar trim as necessary to prevent trim panel interference. (11) Move 2nd row seats to cargo position. (12) Move front seats to fill recline position. (13) Move 3rd row seat to cargo position, if equipped. (14) Remove push-in fasteners attaching headliner to roof panel. (15) Carefully bow headliner and remove through the liftgate opening. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6331 (1) Carefully bow headliner and slide through the liftgate opening. (2) Install push-in fasteners attaching headliner to roof panel. (3) Engage A-pillar, B-pillar, C-pillar, and D-pillar trim. (4) Install upper liftgate opening trim. (5) Install blower control switch for rear air conditioner, if equipped. (6) Install outlet bezel for rear air conditioner, if equipped. (7) Install overhead console, if equipped. (8) Install dome lamp. (9) Install overhead assist handle. (10) Install coat hooks. (11) Install sunvisors and sunvisor arm supports. (12) Return seats to seating position. (13) Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6332 Headliner: Removal and Replacement HEADLINER REMOVAL 1. Disconnect battery negative cable. 2. Remove sunvisors and sunvisor arm supports. 3. Remove coat hooks. 4. Remove overhead assist handle. 5. Remove dome lamp. 6. Remove overhead console, if equipped. 7. Remove outlet bezel for rear air conditioner, if equipped. 8. Remove blower control switch for rear air conditioner, if equipped. 9. Remove upper liftgate opening trim. 10. Disengage A-pillar, B-pillar, C-pillar, and D-pillar trim as necessary to prevent trim panel interference. 11. Move 2nd row seats to cargo position. 12. Move front seats to full recline position. 13. Move 3rd row seat to cargo position, if equipped. Fig. 16 14. Remove push-in fasteners attaching headliner to roof panel (Fig. 16). Fig. 15 15. Carefully bow headliner and remove through the liftgate opening (Fig. 15). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6333 INSTALLATION 1. Carefully bow headliner and slide through the liftgate opening (Fig. 15). 2. Install push-in fasteners attaching headliner to roof panel (Fig. 16). 3. Engage A-pillar, B-pillar, C-pillar, and D-pillar trim. Refer to Trim Panel. 4. Install upper liftgate opening trim. 5. Install blower control switch for rear air conditioner, if equipped. 6. Install outlet bezel for rear air conditioner, if equipped. 7. Install overhead console, if equipped. 8. Install dome lamp. 9. Install overhead assist handle. 10. Install coat hooks. 11. Install sunvisors and sunvisor arm supports. 12. Return seats to seating position. 13. Connect battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair A-PILLAR GRAB HANDLE REMOVAL 1. Using a small flat blade screw driver, pry trim plugs from A-pillar grab handle. 2. Remove screws attaching grab handle to A-pillar. 3. Separate A-pillar grab handle from vehicle. INSTALLATION 1. Position grab handle on A-pillar. 2. Install screws attaching grab handle to A-pillar. 3. Install trim plugs in A-pillar grab handle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair Scuff Plate: Service and Repair LIFTGATE SCUFF PLATE REMOVAL Fig. 18 1. Remove screws attaching cargo tie downs to liftgate scuff plate (Fig. 18). 2. Grasp scuff plate and lift upward to disengage spring clips. 3. Separate scuff plate from liftgate opening. INSTALLATION 1. Position scuff plate in liftgate opening. 2. Press scuff plate to engage spring clips. 3. Install screws attaching cargo tie downs to liftgate scuff plate (Fig. 18). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair SUN VISOR REMOVAL NOTE: All vehicles with driver and passenger side airbags must have a color-coded, 5-bullet point air-bag warning label applied to the sunvisor face surface (in the stored position). When replacing the sunvisor, verify label availability and ensure the label is installed. Fig. 21 1. Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel (Fig. 21). 2. Disengage vanity lamp connector, if equipped. 3. Detach the sunvisor from the visor supports. 4. Remove the sunvisor from the headliner and roof panel. Fig. 22 5. If necessary, grasp both sides of the visor support base and firmly pull outward to disengage the visor support cover from the base (Fig. 22). 6. Lift/rock the visor support upward to disengage it from the roof panel. INSTALLATION 1. If removed, position visor support in roof panel. 2. Push the visor support cover inward and secure the visor support to the roof panel. 3. Position the sunvisor in the visor supports and align the arm support bracket holes with the headliner holes. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Page 6343 4. Engage vanity lamp connector, if equipped. 5. Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures STANDARD PROCEDURE - HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6348 Trim Panel: Removal and Replacement Cowl Trim COWL TRIM COVER REMOVAL 1. Using a trim stick C-4755 or equivalent, pry cowl trim cover from cowl to disengage clips. 2. Separate cowl trim cover from vehicle. INSTALLATION 1. Position cowl trim cover on cowl. 2. Press cowl trim cover into place to engage clips. Door Sill Trim Panel DOOR SILL TRIM REMOVAL 1. Using a trim stick C-4755 or equivalent, pry up door sill trim. 2. Grasp door sill trim and lift upward. Fig. 8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6349 Fig. 9 3. Separate door sill trim from vehicle (Fig. 8) and (Fig. 9). INSTALLATION 1. Position door sill trim on door sill. 2. Press into place. Front Door Trim Panel FRONT DOOR TRIM PANEL REMOVAL 1. Release door latch and open door. 2. Roll window down. Fig. 20 Window Crank Removal Tool 3. Remove window crank, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6350 Fig.19 Door Trim Panel Fig. 22 Trim Panel Screw 4. Remove screws attaching trim panel to door. CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. Fig. 10 Trim Panel Retainer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6351 5. Simultaneously lift upward and outward to release retainer steps from inner door panel. 6. Disengage inside handle linkage rod from inside handle. Fig. 24 Speaker And Power Mirror Connector 7. Disconnect speaker harness wire connector. 8. Disengage power mirror wire connector, if equipped (driver's side only). Fig. 25 Power Door Lock/Window Connector 9. Disengage clips attaching power window/lock switch panel to door trim panel. Disengage wire connector from switch panel, if equipped. 10. Separate door trim panel from vehicle. INSTALLATION 1. Position trim panel at door. 2. Engage wire connector for window/lock switch panel, if equipped. 3. Engage power mirror wire connector, if equipped. 4. Connect speaker harness wire connector. 5. Engage inside handle linkage rod to inside handle. 6. Align trim panel retainer steps with inner door panel and slide trim panel into place. 7. Install screws attaching trim panel to door. 8. Install window crank, if equipped. Liftgate Opening Upper Trim LIFTGATE OPENING UPPER TRIM Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6352 REMOVAL 1. Using a trim stick C-4755 or equivalent, pry upper trim from liftgate opening. 2. Grasp upper trim and pull downward to disengage spring clips. Fig. 17 3. Separate upper trim from liftgate opening (Fig. 17). INSTALLATION 1. Position upper trim in liftgate opening (Fig. 17). 2. Align spring clips and press inward to secure. A-Pillar Trim A-PILLAR TRIM REMOVAL 1. Remove A-pillar grab handle, if equipped. 2. Remove screws from cowl trim cover. 3. Remove cowl trim cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6353 Fig. 1 4. Grasp A-pillar trim and pull outward to disengage clips attaching A-pillar trim to A-pillar (Fig. 1). 5. Separate A-pillar trim from vehicle. INSTALLATION 1. Position A-pillar trim at A-pillar, align clips and press into place. 2. Install cowl trim cover. 3. Install A-pillar grab handle, if equipped. A-Pillar Grab Handle A-PILLAR GRAB HANDLE REMOVAL 1. Using a small flat blade screw driver, pry trim plugs from A-pillar grab handle. 2. Remove screws attaching grab handle to A-pillar. 3. Separate A-pillar grab handle from vehicle. INSTALLATION 1. Position grab handle on A-pillar. 2. Install screws attaching grab handle to A-pillar. 3. Install trim plugs in A-pillar grab handle. B-Pillar Trim B-PILLAR TRIM REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6354 Fig. 2 The upper B-pillar trim is attached to the B-pillar with spring clip retainers. The lower B-pillar trim is attached with screws and spring clip retainers (Fig. 2). 1. Remove front seat belt turning loop cover and turning loop. 2. Grasp upper B-pillar trim and pull outward to release spring clip retainers. 3. Remove door sill trim front and rear. 4. Remove lower B-pillar trim screws. 5. Grasp lower B-pillar trim and pull outward to release spring clip retainers. 6. Route shoulder belt through access slot in lower B-pillar trim. 7. Separate lower B-pillar trim from vehicle. INSTALLATION 1. Position lower B-pillar trim on vehicle. 2. Route shoulder belt through access slot in lower B-pillar trim. 3. Press lower B-pillar trim inward to engage spring clip retainers. 4. Position upper B-pillar trim on vehicle. 5. Press upper B-pillar trim inward to engage spring clip retainers. 6. Install B-pillar trim screws. 7. Install door sill trim front and rear. 8. Install front seat belt turning loop, and tighten bolt to 39 N.m (29 ft. lbs.). 9. Install turning loop cover. C-Pillar Trim C-PILLAR TRIM REMOVAL 1. Remove cover and bolt attaching 2nd row seat belt turning loop to C-pillar. 2. Grasp C-pillar trim and pull outward to disengage spring clips. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6355 Fig. 7 3. Separate C-pillar trim from C-pillar (Fig. 7). INSTALLATION 1. Position C-pillar trim on C-pillar (Fig. 7). 2. Align spring clips and press into place. 3. Install bolt attaching 2nd row seat belt turning loop to C-pillar and tighten to 39 N.m (29 ft. lbs.). 4. Install turning loop cover. D-Pillar Trim D-PILLAR TRIM REMOVAL 1. Remove liftgate opening upper trim. 2. Remove screw attaching D-pillar trim to upper liftgate opening. 3. Remove 3rd row seat, if equipped. 4. Remove nut attaching 3rd row seat belt anchor to quarter panel, if equipped. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6356 Fig. 10 5. Remove bolt attaching 3rd row seat belt turning loop to D-pillar, if equipped (Fig. 10). 6. Remove two screws secureing D-pillar trim to D-pillar. 7. Grasp upper edge of D-pillar trim and carefully pull outward to disengage upper spring clips. 8. Lift D-pillar trim upward to release it from the quarter panel trim. 9. Route 3rd row seat belt through access slot, if equipped. 10. Separate D-pillar trim from vehicle. INSTALLATION 1. Route 3rd row seat belt through access slot, if equipped. 2. Position D-pillar trim on D-pillar. 3. Slid D-pillar trim downward to engage it with the quarter panel trim. 4. Align D-pillar trim upper spring clips and press inward to engage. 5. Install screws attaching D-pillar trim to upper liftgate opening. 6. Install liftgate opening upper trim. 7. Install bolt attaching 3rd row seat belt turning loop to D-pillar, if equipped (Fig. 10) and tighten to 39 N.m (29 ft. lbs.). 8. Install nut attaching 3rd row seat belt anchor to quarter panel, if equipped, and tighten to 39 N.m (29 ft. lbs.). 9. Install 3rd row seat, if equipped. Quarter Panel Trim QUARTER PANEL TRIM REMOVAL 1. Tumble 2nd row seats to cargo position. 2. Remove 3rd row seat, if equipped. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Remove D-pillar trim. Refer to Trim Panel. 5. Remove liftgate opening scuff pad. 6. Remove screws attaching quarter panel trim to C-pillar and D-pillar. 7. Route 2nd row seat belt through access slot in quarter panel trim. 8. Grasp quarter panel trim and pull outward to disengage spring clips. 9. Separate quarter panel trim from vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 6357 INSTALLATION 1. Position quarter panel trim in vehicle. 2. Route 2nd row seat belt through access slot in quarter panel trim. 3. Align quarter panel trim spring clips and press inward to engage. 4. Install screws attaching quarter panel trim to C-pillar and D-pillar. 5. Install D-pillar trim. 6. Install C-pillar trim. 7. Install liftgate opening scuff pad. 8. Install 3rd row seat, if equipped. 9. Return 2nd row seats to seating position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Rear Storage Box Utility Storage Compartment: Service and Repair Rear Storage Box REAR STORAGE BOX REMOVAL FLOOR CARGO STORAGE DOOR THIRD ROW SEAT EQUIPPED The floor cargo storage door is attached to the cargo area carpet. NON-THIRD ROW SEAT EQUIPPED 1. Fold rear seat forward. Fig. 19 2. Remove the four bolts and remove the storage box (Fig. 19). INSTALLATION THIRD ROW SEAT EQUIPPED The floor cargo storage door is attached to the cargo area carpet. NON-THIRD ROW SEAT EQUIPPED 1. Install the storage box. 2. Install the bolts and tighten to 3 N.m (25 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Rear Storage Box > Page 6362 Utility Storage Compartment: Service and Repair Storage Bin STORAGE BIN REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Fig. 16 3. Remove the three screws that secure the storage bin to the back of the cluster bezel (Fig. 16). 4. Remove the storage bin from the back of the cluster bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the storage bin onto the back of the cluster bezel (Fig. 16). 2. Install and tighten the three screws that secure the storage bin to the back of the cluster bezel. Tighten the screws to 2 N.m (20 in. lbs.). 3. Reinstall the cluster bezel onto the instrument panel. 4. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Door Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6373 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6374 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6375 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Door Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6381 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6382 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6383 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 6384 Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove door trim panel. 2. Remove outside handle. 3. Disengage lock cylinder to latch rod from the lock cylinder. Fig. 9 4. Using a small flat blade, pry lock cylinder retaining clip from lock cylinder housing/outside handle (Fig. 9). 5. Push lock cylinder out of lock cylinder housing/outside handle. INSTALLATI0N 1. Push lock cylinder into lock cylinder housing/outside handle. Ensure the lock cylinder is fully seated in the handle. 2. Install lock cylinder retaining clip. Ensure the clip is fully seated. 3. Engage lock cylinder to latch rod to the lock cylinder. 4. Install outside handle. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation The Remote Keyless Entry (RKE) receiver is a radio frequency unit that is integral to the high-line version of the Central Timer Module (CTM). The CTM also contains the program logic and control circuitry for the RKE system. The CTM is mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The RKE receiver has a memory function to retain the vehicle access codes of up to four RKE transmitters. The receiver is designed to retain the transmitter codes in memory, even if the battery is disconnected. The RKE receiver is energized by one of three radio frequency inputs from the RKE transmitter; Unlock, Lock, or Panic. The programming of the CTM responds to these RKE inputs, as well as many other inputs, by sending the proper control outputs to the power lock motors, the courtesy lamp circuit, the driver unlock relay, the horn relay, and the headlamp relay. For diagnosis or programming of the RKE receiver within the high-line CTM, a DRB scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or another suitable wide fiat-bladed tool, gently pry at the center seam of the transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the transmitter. 3. Remove the two batteries from the transmitter. 4. Replace the two batteries with new Duracell DL2016, or their equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two transmitter case halves with each other, and squeeze them firmly together until they snap back into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications Power Door Lock Actuator: Specifications Power Lock Motor Mounting Screws 3.3 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6397 Power Door Lock Actuator: Description and Operation In the power lock and Remote Keyless Entry (RKE) systems, the door and liftgate latch lock mechanisms can be actuated by a reversible electric motor. The power lock motor is integral to the door latch mounted within each door. A separate power lock motor is used to actuate the liftgate latch. The power lock motor direction is controlled by the battery and ground feeds from the power lock and unlock relays, which are integral to the high-line Central Timer Module (CTM). The RKE receiver within the CTM can also unlock just the driver door through a separate driver door unlock relay that is located in the relay and fuse block attached to the back of the junction block under the instrument panel. The power door lock motors cannot be repaired and, if faulty or damaged, the entire door latch unit must be replaced. The power liftgate lock motor is serviced separately. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6398 Power Door Lock Actuator: Testing and Inspection Before you proceed with this diagnosis, confirm proper power lock switch, Central Timer Module (CTM) and power lock switch output circuit operation. Remember, the CTM circuitry controls the output to each of the power lock motors. 1. Check each power lock motor for correct operation while moving the power lock switch to both the Lock and Unlock positions. If all of the power lock motors are inoperative, go to Step 2. If one power lock motor is inoperative, go to Step 3. 2. If all of the power lock motors are inoperative, the problem may be caused by one shorted motor. Unplugging a shorted power lock motor from the power lock circuit will allow the good power lock motor to operate. Unplug each power lock motor wire harness connector, one at a time, and recheck both the lock and unlock functions by operating the power lock switch. If all of the power lock motors are still inoperative after the above test, check for a short or open circuit between the power lock motors and the CTM. If unplugging one power lock motor causes the other motor to become functional, go to Step 3 to test the unplugged motor. 3. Once it is determined which power lock motor is inoperative, that motor can be tested as follows. Unplug the wire harness connector at the inoperative power lock motor. Apply 12 volts to the motor terminals to check its operation in one direction. Reverse the polarity to check the operation in the other direction. If OK, repair the short or open circuits between the power lock motor and the CTM as required. If not OK, replace the faulty power lock motor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 6399 Power Door Lock Actuator: Service and Repair REMOVAL DOOR The power lock motor is integral to the door latch unit. If the power lock motor is faulty or damaged, the entire door latch unit must be replaced. LIFTGATE 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inner liftgate panel. Liftgate Power Lock Motor Remove/Install 3. Remove the two screws that secure the power lock motor to the liftgate inner panel. 4. Pull the power lock motor out through the access hole in the liftgate inner panel far enough to access and unplug the wire harness connector. 5. Lower the power lock motor far enough to access and disengage the link from the liftgate latch clip. 6. Remove the power lock motor from the liftgate. 7. Reverse the removal procedures to install. Tighten the mounting screws to 3.3 Nm (30 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6403 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6404 Power Door Lock Relay: Description and Operation The driver unlock 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 6405 Power Door Lock Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6409 Power Door Lock Switch: Description and Operation The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6410 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity. See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off; Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the body half of the power lock switch wire Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6411 harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6412 Power Door Lock Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove liftgate trim panels 2. Remove liftgate handle. 3. Remove clip retaining lock cylinder in outside handle. 4. Remove the clip retaining actuator link to lock cylinder. Remove actuator link. Fig. 6 5. Separate lock cylinder from handle (Fig. 6). INSTALLATION 1. Position lock cylinder in outside handle (Fig. 6). 2. Install clip retaining lock cylinder in handle. 3. Install actuator link and retaining clip. 4. Install liftgate handle. 5. Install liftgate trim panels. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation HEATED MIRROR SYSTEM The heated mirror system will only operate when the ignition switch is in the ON position. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. The heated mirror system is controlled by a momentary rear window defogger switch in the rear window switch pod installed in the instrument panel lower bezel, which also includes the switch for the rear wiper and washer system. An amber indicator lamp in the switch pod will light to indicate when the defogger system is turned on. The rear window switch pod also contains the defogger system control circuitry including the timer logic and the defogger relay. The heated mirror system only operates in concert with the rear defogger system, and will be automatically turned OFF after a programmed time interval of about ten minutes. After the initial time interval has expired, if the defogger switch is turned ON again during the same ignition cycle, the heated mirror system will automatically turn OFF after about five minutes. The heated mirror system will automatically shut OFF if the ignition switch is turned to the OFF position, or it can be turned OFF manually by depressing the defogger switch a second time. Following are general descriptions of the major components in the heated mirror system. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement.The heated mirror system will only operate when the ignition switch is in the ON position. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6423 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Control Knob Remove/Install - Typical 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut - Typical 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6424 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID Exterior Color Interior Color Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 6429 Paint: Description and Operation BASECOAT/CLEARCOAT FINISH DESCRIPTION The original equipment finish is a multi step process that involves cleaning, applying electro deposition (E-coat), anti-chip primer, basecoat, and clearcoat steps. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: - Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. - Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use MOPAR Scratch Filled Primer, Touch-Up Paints and Clear Top Coat. WARNING: USE AN OSHA APPROVED RESPIRATOR AND SAFETY GLASSES WHEN SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PERSONAL INJURY CAN RESULT. STANDARD PROCEDURE-PAINT TOUCH-UP 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with MOPAR Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filled primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filled primer to dry hard. 4. Cover the filled primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL-BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL-BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 6432 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING & POLISHING DESCRIPTION CAUTION: Do not remove more than 0.5 mils of clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine film thickness before and after the repair. Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6437 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6438 Power Door Lock Relay: Description and Operation The driver unlock 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the Remote Keyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panel in the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 6439 Power Door Lock Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. Relay And Fuse Block 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Unplug the driver unlock relay from the relay and fuse block. 5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place. 6. Connect the battery negative cable. 7. Test the relay operation. 8. Reverse the remaining removal procedures to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 6443 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 6444 Trailer Towing Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair Luggage Rack: Service and Repair LUGGAGE RACK REMOVAL Fig. 10 1. Remove screws attaching side rail to roof panel (Fig. 10). 2. Separate luggage rack from vehicle. NOTE: The skid strips are attached to roof panel with adhesive. 3. Loosen each skid strip with a heat gun. 4. Lift one edge of each skid strip with a putty knife and peel it from roof panel. Apply additional heat to any location where a skid strip remains. 5. Remove original adhesive from roof panel with an all-purpose adhesive removal solution. INSTALLATION NOTE: Thoroughly clean and prepare the roof surface. 1. Align each skid strip on roof panel. 2. Verify that each skid strip is properly aligned. 3. Remove the carrier backing and press each skid strip onto roof panel with a roller. NOTE: Apply 3M Drip-Chek Sealant (or an equivalent product) to side rail screw threads. 4. Position luggage rack on roof. 5. Install screws attaching side rail to roof panel (Fig. 10). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6454 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6455 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6456 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6457 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6458 TIME ALLOWANCE: FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair Head Rest: Service and Repair HEADREST SLEEVE REMOVAL NOTE: When removing the head restraint sleeves and guides, the retaining tabs on the sleeves will be damaged during the removal process. Check the availability of replacement parts before servicing. 1. Remove head restraint. Fig. 1 2. Using a trim stick C-4755 or equivalent, pry head restraint sleeves and guides from seat back. (Fig. 1). 3. Separate head restraint sleeves and guides from seat back and discard. INSTALLATION 1. Position new head restraint sleeves and guides in seat back. 2. Rotate head restraint sleeve until aligned with slot in the guide and press downward to secure. Ensure head restraint sleeve is anchored securely. 3. Install head restraint. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation Power Seat Motor: Description and Operation There are three reversible motors that operate the power seat adjuster. The motors are connected to worm-drive gearboxes that move the seat adjuster through a combination of screw-type drive units, The front and rear of a seat are operated by different motors. They can be raised or lowered independently of each other. When the center seat switch is pushed to the Up or Down position, both the front and rear motors operate in unison, moving the entire seat up or down. The forward-rearward motor is operated by pushing the center seat switch to the Forward or Rearward position. When a switch is actuated, a battery feed and a ground path are applied through the switch contacts to the motor(s). The motor(s) and drives operate to move the seat in the selected direction until the switch is released, or until the travel limit of the power seat adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor(s) are reversed through the switch contacts. This causes the motor to run in the opposite direction. Each motor contains a self-resetting circuit breaker to protect it from overload. Consecutive or frequent resetting of the circuit breakers must not be allowed to continue, or the motors may be damaged. Make the necessary repairs. The power seat adjuster and motors cannot be repaired, and are serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat adjuster and motors assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6465 Power Seat Motor: Testing and Inspection Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat adjuster fails to operate in only one direction, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power seat adjuster still fails to operate in only one direction, see Power Seat Switch. If the power seat adjuster fails to operate in more than one direction, proceed as follows: 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the PDC as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch as described. If the switch tests OK, check the wire harness for the inoperative power seat motor(s) between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the faulty power seat adjuster and motors assembly. If the circuits are not OK, repair the wire harness as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Description and Operation > Page 6466 Power Seat Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side seat, adjuster and motors assembly from the vehicle as a unit. 3. Unplug the power seat wire harness connectors at each of the three power seat motors. 4. Release the power seat wire harness retainers from the seat adjuster and motors assembly. 5. Remove the four screws that secure the power seat adjuster and motors assembly to the seat cushion frame. 6. If the vehicle is equipped with a split bench seat, remove the fasteners that secure the center seat cushion to the brackets on the power seat adjuster. 7. Remove the power seat adjuster and motors assembly from the seat cushion frame. CAUTION: Before installing the seat into the vehicle, be certain to adjust the seat fully rearward on its tracks. Then install and tighten the front track mounting screws before installing the rear screws or the tracks may be damaged. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6470 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6471 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Specifications > Page 6472 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Back: Customer Interest Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: 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. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6481 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Back: All Technical Service Bulletins Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: 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. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6487 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Latch: Customer Interest Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: 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. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6496 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position Seat Latch: All Technical Service Bulletins Seat - Rattle/Chuck in Upright Position NUMBER: 23-31-00 GROUP: Body DATE: August 18, 2000 SUBJECT: Rattle/Chuck In The Second Row Seat When Seat Is In Upright Position OVERVIEW: This bulletin involves installing revised outboard seat back latches on both right side and left side second row seats. MODELS: 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 40/20/40 SECOND ROW SPLIT BENCH SEAT (SALES CODE CFM). SYMPTOM/CONDITION: The 40/20/40 second row split bench seat back may chuck or rattle while in the upright and locked position when going over bumps. DIAGNOSIS: With the second row seat latched in the upright position, firmly grab the seat back on the upper outboard corner of either 40% portion of the second row seat and push in a fore-aft motion. If the seat latch rattles when you push the seat back fore and aft, perform the Repair Procedure. PARTS REQUIRED: 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. Tumble the seat forward. 2. Remove the screw that secures the outboard latch release handle and remove the handle. 3. Remove the three screws that secure the outboard latch cover and remove the latch cover. 4 Disengage the seat cover hook-and-arrow on the outboard side of the seatback (Figure 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-31-00 > Aug > 00 > Seat - Rattle/Chuck in Upright Position > Page 6502 5. Remove bolts attaching the outboard latch to the seat cushion and seat back frame. 6. Disconnect the cable to the outboard latch. 7. Connect the cable to the new outboard latch (see Parts Required section). 8. Install the new outboard latch onto the seat cushion and seat back frame. Tighten the bolt located in the round hole first, than the bolts located in the slotted holes (Figure 2). Tighten the bolts to 27 N.m (19 ft.lbs.). NOTE: THE SEAT MUST BE IN THE FORWARD TUMBLED POSITION PRIOR TO TIGHTENING THE NEW OUTBOARD LATCH. FAILURE TO TIGHTEN THE LATCH IN THIS POSITION COULD RESULT IN LOOSENESS BETWEEN THE LATCH AND THE SEAT CUSHION FRAME CAUSING A CHUCK/RATTLE IN THE OUTBOARD LATCH. 9. Engage the seat cover hook-and-arrow on the outboard side of the seatback. 10. Install the outboard latch cover and secure it with the three screws. 11. Install the outboard latch release handle and secure it with the screw. 12. Remove and install the second row outboard latch on the other seat using the procedure described in Steps 1 through 11. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-27-00 > Jul > 00 > Power Seat - Creaking Noise Seat Track: Customer Interest Power Seat - Creaking Noise NUMBER: 23-27-00 GROUP: Body DATE: July 7, 2000 SUBJECT: Power Seat Track Creak OVERVIEW: This bulletin involves repositioning and lubricating the power seat track-locating pin. MODELS: 2000 (AN) Dakota 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO ALL DAKOTA QUAD CAB VEHICLES AND DURANGO VEHICLES BUILT AFTER DECEMBER 11, 1999 (MDH 121110) EQUIPPED WITH EITHER THE 40/20/40 SPLIT BENCH (SALES CODE CBE) OR BUCKET FRONT SEAT (SALES CODE CAD) WITH THE DRIVER SIDE POWER SEAT ADJUSTMENT OPTION (SALES CODE JPS). SYMPTOM/CONDITION: Driver power seat creaks at front outboard attachment when shifting weight or driving over bumpy roads. DIAGNOSIS: While sitting in the seat, firmly shift weight from side to side of the seat. If a creaking noise is heard coming from the outboard front attachment area of the seat, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318066 Lubricant, Spray White REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the outboard power seat track cover (Durango Only) by removing the two phillips head screws and unsnapping the cover. 2. Remove both front M8 attaching bolts. 3. With the two rear bolts still attached, lift the outboard seat track foot slightly (no more than one inch) to expose the locator pin. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-27-00 > Jul > 00 > Power Seat - Creaking Noise > Page 6511 4. Spray lubricant pin 04318066 around locating pin (Figure 1). Be careful to ensure that white lubricant does not get on the carpet. 5. Position the locating pin of the outboard foot of the power seat track in the center of the locating hole (no metal-to-metal contact). It may be required to loosen the rear power seat track attaching bolts in order to be able to position the locator pin into the center of the locator hole. 6. Secure the power seat track by installing the front M8 attaching bolts and tightening all fasteners (front and rear) to 27 Nm (20 ft.lb.). 7. Attach the power seat track covers (Durango only). 8. Verify the repair by performing the diagnosis again. Repeat the process until repair is successful. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-13-60-94 0.2 Hrs. FAILURE CODE: 68 - Noisy Disclaimer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-27-00 > Jul > 00 > Power Seat - Creaking Noise Seat Track: All Technical Service Bulletins Power Seat - Creaking Noise NUMBER: 23-27-00 GROUP: Body DATE: July 7, 2000 SUBJECT: Power Seat Track Creak OVERVIEW: This bulletin involves repositioning and lubricating the power seat track-locating pin. MODELS: 2000 (AN) Dakota 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO ALL DAKOTA QUAD CAB VEHICLES AND DURANGO VEHICLES BUILT AFTER DECEMBER 11, 1999 (MDH 121110) EQUIPPED WITH EITHER THE 40/20/40 SPLIT BENCH (SALES CODE CBE) OR BUCKET FRONT SEAT (SALES CODE CAD) WITH THE DRIVER SIDE POWER SEAT ADJUSTMENT OPTION (SALES CODE JPS). SYMPTOM/CONDITION: Driver power seat creaks at front outboard attachment when shifting weight or driving over bumpy roads. DIAGNOSIS: While sitting in the seat, firmly shift weight from side to side of the seat. If a creaking noise is heard coming from the outboard front attachment area of the seat, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04318066 Lubricant, Spray White REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the outboard power seat track cover (Durango Only) by removing the two phillips head screws and unsnapping the cover. 2. Remove both front M8 attaching bolts. 3. With the two rear bolts still attached, lift the outboard seat track foot slightly (no more than one inch) to expose the locator pin. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-27-00 > Jul > 00 > Power Seat - Creaking Noise > Page 6517 4. Spray lubricant pin 04318066 around locating pin (Figure 1). Be careful to ensure that white lubricant does not get on the carpet. 5. Position the locating pin of the outboard foot of the power seat track in the center of the locating hole (no metal-to-metal contact). It may be required to loosen the rear power seat track attaching bolts in order to be able to position the locator pin into the center of the locator hole. 6. Secure the power seat track by installing the front M8 attaching bolts and tightening all fasteners (front and rear) to 27 Nm (20 ft.lb.). 7. Attach the power seat track covers (Durango only). 8. Verify the repair by performing the diagnosis again. Repeat the process until repair is successful. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-13-60-94 0.2 Hrs. FAILURE CODE: 68 - Noisy Disclaimer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6522 Power Door Lock Switch: Description and Operation The power locks can be controlled by a two-way switch integral to the power window and lock switch unit on the driver side front door trim panel, or a two-way single gang switch on the passenger side front door trim panel. The power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The CTM then relays the correct battery and ground feeds to the power lock motors. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. The driver side power window and lock switch unit cannot be repaired and, if faulty or damaged, the entire switch unit must be replaced. The passenger side power lock switch cannot be repaired and, if faulty or damaged, the switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6523 Power Door Lock Switch: Testing and Inspection If the problem being diagnosed involves only the power lock switch illumination LEDs, check the fused ignition switch output (run) and ground circuits at the power lock switch connector. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the power lock switch. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity. See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Off; Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the body half of the power lock switch wire Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6524 harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6525 Power Door Lock Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the passenger side front door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power mirror switch knob is available for service replacement.The heated mirror system will only operate when the ignition switch is in the ON position. When the rear window defogger switch is in the ON position, an electric heater grid located behind the glass of each of the outside rear view mirrors is energized. When energized, each of these heater grids produce heat to help clear the outside rear view mirrors of ice, snow, or fog. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6529 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Control Knob Remove/Install - Typical 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut - Typical 3. Remove the nut that secures the power mirror switch to the driver side door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door panel far enough to access the power mirror switch wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6530 Door Trim Panel Wire Harness Connectors 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications Power Seat Switch: Specifications Power Seat Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6534 Power Seat Switch: Description and Operation The power seat can be adjusted in six different ways using the power seat switch. The switch is located on the lower outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch unit cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6535 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors in the Diagnosis and Testing. If not OK, replace the faulty power seat switch unit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Specifications > Page 6536 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Unplug the wire harness connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: Customer Interest Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6546 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6547 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks - Intermittently Lock/Unlock by Themselves > Page 6548 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves Tailgate Lock Cylinder: All Technical Service Bulletins Power Locks - Intermittently Lock/Unlock by Themselves NUMBER: 08-023-03 GROUP: Electrical DATE: July 18, 2003 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-041-00, DATED DEC. 15, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION ADDS 2002 AND 2003 VEHICLES AND REVISES THE PARTS TABLE. SUBJECT: Intermittent Locking/Unlocking Of Doors Without Activating The Power Door Lock Switch OVERVIEW: This bulletin involves installing new door/liftgate lock cylinder switches. MODELS: **2000 - 2003** (AB) Ram Van/Wagon **2000 - 2003** (AN) Dakota **2000 - 2002** (BR/BE) Ram Truck **2000 - 2003** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH VEHICLE THEFT SECURITY SYSTEM (SALES CODE LSA). SYMPTOM/CONDITION: The door locks will intermittently lock and/or unlock without any activation of the power door lock switch or a clicking sound may be heard coming from the power door locks (repeated locking or repeated unlocking). The condition may occur more frequently in damp conditions such as driving the vehicle in the rain or taking the vehicle through a car wash. DIAGNOSIS: Vehicles that demonstrate this condition may have water weeping into the door/liftgate lock cylinder switches causing the switch to intermittently short across the internal circuit. This in turn may signal the Central Timer Module (CTM) to activate the power door locks. Because of the nature of this problem, it is extremely difficult to diagnose this condition. Therefore, customers that indicate their doors intermittently lock and unlock without having the door lock switch activated or customers that indicate they hear a repeated clicking noise coming from the door locks should have the Repair Procedure performed on their vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6554 PARTS REQUIRED: NOTE: **The passenger side door lock cylinder switch has been eliminated on 2002 and 2003 Durangos and on 2003 Dakotas built after April 7, 2003 (MDH 0407XX)**. REPAIR PROCEDURE: 1. Remove the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. 2. The door lock cylinder switch actuator must be positioned in its neutral position prior to installing the new switch on the lock cylinder. Rotate the actuator until the actuator is positioned as shown in the following figure (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6555 3. Install the driver, passenger (if equipped), and liftgate (Durango only) door lock cylinder switches. Refer to the appropriate Service Manual Group 8Q, pages 8QA and 8Q-5 or the service information available in the MDS2 for DOOR LOCK CYLINDER SWITCH and/or LIFTGATE LOCK CYLINDER SWITCH - REMOVAL AND INSTALLATION procedures. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 08-023-03 > Jul > 03 > Power Locks Intermittently Lock/Unlock by Themselves > Page 6556 FAILURE CODE: Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE AND SCREEN REMOVAL 1. Open hood. 2. Remove the wiper arms. Fig. 4 3. Remove upper plastic nuts attaching cowl grille to cowl (Fig. 4). 4. Insert a small flat blade into the slots of the plastic rivet anchors in each cowl grille corner. Lift up on the flat blade to release the rivet anchors. 5. Remove cowl weatherstrip. 6. Disconnect and plug windshield washer feed line from cowl. 7. Disconnect vacuum line from cowl. 8. Separate cowl grille from cowl. INSTALLATION 1. Position cowl grille on cowl. 2. Connect vacuum line to cowl. 3. Remove the plug and connect windshield washer feed line to cowl. 4. Install cowl weatherstrip. 5. Position rivet anchors in place and press down to engage. 6. Install upper plastic nuts attaching cowl grille to cowl. 7. Install the wiper arms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal Front Door Weatherstrip: Service and Repair Front Door Secondary Seal FRONT DOOR SECONDARY SEAL REMOVAL 1. Remove the push-in fasteners attaching the secondary seal to the inner door panel. 2. Separate the secondary seal from the inner door panel. INSTALLATION 1. Position the secondary seal on the inner door panel. 2. Install the push-in fasteners attaching the secondary seal to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6567 Front Door Weatherstrip: Service and Repair Front Door Weatherstrip FRONT DOOR WEATHERSTRIP REMOVAL 1. Remove A-pillar trim. Refer to Trim Panel. 2. Remove lower cowl trim. 3. Remove door sill trim. 4. Loosen upper and lower B-pillar trim to access weatherstrip. Fig. 3 5. Pull weatherstrip from pinch flange around door opening (Fig. 3). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Press B-pillar trim into place. 4. Install lower cowl trim. 5. Install door sill trim. 6. Install A-pillar trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6568 Front Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Secondary Seal > Page 6569 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6574 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6575 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 6576 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal Hood Weatherstrip: Service and Repair Hood Seal HOOD SEAL REMOVAL Fig. 2 1. Remove push-in fasteners attaching hood seal to inner hood panel (Fig. 2). 2. Separate hood seal from vehicle. INSTALLATI0N 1. Position hood seal on inner hood panel. 2. Install push-in fasteners attaching hood seal to inner hood panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Seal > Page 6581 Hood Weatherstrip: Service and Repair Cowl Weatherstrip COWL WEATHERSTRIP REMOVAL Fig. 1 1. Grasp cowl seal and pull seal from flange (Fig. 1). 2. Separate cowl seal from vehicle. INSTALLATION 1. Position cowl seal on flange and press into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal Rear Door Weatherstrip: Service and Repair C-Pillar Seal C-PILLAR SEAL REMOVAL-C-PILLAR SEAL NOTE: The seal is attached to the door with adhesive tape. Fig. 11 1. Peel the seal from the door (Fig. 11). INSTALLATION-C-PILLAR SEAL 1. Clean the contact area with Mopar(R) Super Kleen or equivalent. 2. Remove the carrier for the seal 3. Align the seal on the door and press into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6586 Rear Door Weatherstrip: Service and Repair Rear Door Secondary Weatherstrip REAR DOOR SECONDARY WEATHERSTRIP REMOVAL Fig. 7 1. Separate the secondary seal from the inner door panel (Fig. 7). INSTALLATION 1. Thoroughly clean the area of old adhesive. Use Mopar(R) Super Kleen or equivalent. 2. Position the secondary seal on the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6587 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip REAR DOOR WEATHERSTRIP REMOVAL 1. Remove door sill trim. 2. Loosen upper and lower B-pillar trim to access weatherstrip. 3. Remove C-pillar trim. Refer to Trim Panel. 4. Pull quarter panel trim outward to access weatherstrip. Fig. 8 5. Pull weatherstrip from pinch flange around door opening (Fig. 8). INSTALLATION 1. Clean pinch flange 2. Position the weatherstrip on the pinch flange around door opening and press into place. 3. Reposition quarter panel trim. 4. Install C-pillar trim. 5. Reposition B-pillar trim. 6. Install door sill trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6588 Rear Door Weatherstrip: Service and Repair Roof Rail Weatherstrip/Retainer ROOF RAIL WEATHERSTRIP/RETAINER REMOVAL 1. Release door latch and open door. 2. The rearward corner of the weatherstrip is adhesively attached to the body. Peel back the corner of the weatherstrip to release it from the body. Fig. 9 3. Pull weatherstrip from retainer (Fig. 9). Fig. 10 4. Remove screws attaching retainer to roof rail (Fig. 10). 5. Separate retainer from vehicle. INSTALLATION NOTE: The screws attaching the retainer to the roof are coated with wax to prevent water leakage. If the retainer has been removed from the roof, replace the screws. 1. Ensure the area where tape secures the weatherstrip is clean. Use Mopar(R) Super Clean or equivalent. 2. Position retainer on vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > C-Pillar Seal > Page 6589 3. Install screws attaching retainer to roof rail. 4. Starting at the forward end of retainer, push weatherstrip on until seated. 5. Peel the backing from the rearward end of the weatherstrip and press to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6594 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6595 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 6596 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair LIFTGATE OPENING WEATHERSTRIP REMOVAL 1. Remove liftgate opening upper trim. 2. Remove liftgate opening scuff plate. Fig. 4 3. Pull weatherstrip from liftgate opening (Fig. 4). INSTALLATION 1. Position weatherstrip in liftgate opening and align corners (Fig. 4). 2. Press weatherstrip onto flange and carefully place over quarter panel trim. 3. Connect ends at bottom/center of liftgate opening. 4. Install liftgate opening scuff plate. 5. Install liftgate opening upper trim. 6. Carefully place weatherstrip over trim using a fiber stick. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 6604 Brake Switch (Cruise Control): Description and Operation The switch is mounted on the brake pedal mounting bracket under the instrument panel. Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged). The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal. With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low. The low voltage signal, monitored by the PCM, indicates that the brakes are not applied. When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on. Through the brake switch, current is routed to the speed control servo solenoids. The speed control solenoids (vacuum, vent and dump) are provided this current any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and current is interrupted to the solenoids. The normally open contacts are fed battery voltage. When the brakes are applied, battery voltage is supplied to the brake lamps. The Tail lamps on the Durango are mounted at the rear of the vehicle, outboard of the rear hatch and integrated into the lines of the vehicle. The tail lamp module contains a housing, lens, and three bulbs. Dual filament bulb is used for tail, stop, and turn signal operations. A separate bulb is used for back-up illumination. Tail lamp functions are controlled by the headlamp switch. Turn signal operations are controlled by the multifunction switch. Stop lamp functions are controlled by the stoplamp switch. The back-up lamps are controlled by the back-up lamp switch on the transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Servo Mounting Bracket-to-Servo Nuts 8.5 Nm Servo Mounting Bracket-to-Body Nuts 7-10 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6608 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6609 Vehicle Speed Control Servo Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6610 Cruise Control Servo: Description and Operation The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. The Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph to resume, 35 mph to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6611 Cruise Control Servo: Testing and Inspection REMOVAL 1. Disconnect negative battery cable at battery. Speed Control Servo Location 2. Disconnect vacuum hose (line) at servo. 3. Disconnect electrical connector at servo. 4. Disconnect servo cable at throttle body. Servo Cable Clip Remove/Install - Typical 5. Remove 2 mounting nuts holding servo cable sleeve to bracket. 6. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip and remove clip. Note: The servo mounting bracket displayed in is a typical bracket and may/may not be applicable to this model vehicle. 7. Remove servo from mounting bracket. While removing, note orientation of servo to bracket. INSTALLATION 1. Position servo to mounting bracket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6612 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install servo mounting nuts and tighten to 8.5 Nm (75 in. lbs.). 5. Connect vacuum line at servo. 6. Connect electrical connector at servo. 7. Connect servo cable to throttle body. 8. Connect negative battery cable to battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6613 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. Speed Control Servo Location 2. Disconnect vacuum hose (line) at servo. 3. Disconnect electrical connector at servo. 4. Disconnect servo cable at throttle body. Servo Cable Clip Remove/Install - Typical 5. Remove 2 mounting nuts holding servo cable sleeve to bracket. 6. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip and remove clip. Note: The servo mounting bracket displayed in is a typical bracket and may/may not be applicable to this model vehicle. 7. Remove servo from mounting bracket. While removing, note orientation of servo to bracket. INSTALLATION 1. Position servo to mounting bracket. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 6614 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install servo mounting nuts and tighten to 8.5 Nm (75 in. lbs.). 5. Connect vacuum line at servo. 6. Connect electrical connector at servo. 7. Connect servo cable to throttle body. 8. Connect negative battery cable to battery. 9. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6618 Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Locations > Page 6619 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery Cable Connection at Throttle Body 2. Using finger pressure only, remove speed control cable connector at throttle body bellcrank by pushing connector off the bellcrank pin, DO NOT try to pull connector off perpendicular to the bellcrank pin. Connector Will be broken. 3. Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket (locking plate) and push out of bracket. 4. Remove servo cable from servo. INSTALLATION 1. Install end of cable to speed control servo. 2. Install cable into throttle body mounting bracket (snaps in). 3. Install speed control cable connector at throttle body bellcrank pin (snaps on). 4. Connect negative battery cable at battery. 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws 1.5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6623 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6624 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6625 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6626 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6627 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations Cruise Control Vacuum Reservoir: Locations Vacuum Reservoir Mounting The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 6631 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. The vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating(air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 6632 Cruise Control Vacuum Reservoir: Service and Repair Vacuum Reservoir Mounting The vacuum reservoir is located under the plastic cowl plenum cover at lower base of windshield. REMOVAL 1. Disconnect and isolate negative battery at cable. 2. Remove both windshield wiper arm/blade assemblies. Cowl Grille Panel Weather-strip 3. Remove rubber weather-strip at front edge of cowl grill. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 6633 Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove four plastic nuts securing cowl plenum cover/grille panel to studs on cowl top panel near base of windshield. 5. Remove two plastic rivets securing each side of the cowl plenum cover/grille panel to cowl plenum panel and cowl top panel. 6. Lift cowl plenum cover/grille panel from vehicle far enough to access windshield washer and vacuum plumbing near right end of cowl plenum. 7. Disconnect windshield washer supply hose at in-line connector. 8. Disconnect vacuum supply hose from vacuum supply connector at vacuum reservoir. 9. Remove cowl plenum cover/grille panel from vehicle. 10. Remove three reservoir mounting screws. 11. Remove vacuum reservoir from vehicle. INSTALLATION 1. Install vacuum reservoir and three mounting screws to plastic cowl cover. Tighten three screws to 2.2 Nm (20 in. lbs.) torque. 2. Position cowl plenum cover/grille panel to vehicle. 3. Connect vacuum supply hose to vacuum reservoir. 4. Connect windshield washer supply hose at inline connector. 5. Install and tighten cowl cover fasteners to vehicle body. 6. Install rubber weather-strip at front edge of cowl grill. 7. Install windshield wiper arms. 8. Connect negative battery to cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation When all of the speed control parameters are met, and the SET button is pressed, the PCM actuates the vent solenoid and "duty-cycles" the vacuum solenoid to open the throttle and bring the vehicle up to target speed. When the vehicle is at target speed, it will actuate the vent solenoid with the vacuum solenoid de-activated to maintain the vehicle at target speed. When the vehicle is above target speed, the PCM will "duty-cycle" the vent solenoid with the vacuum solenoid still de-activated to close the throttle to return to target speed. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations The switch is mounted on the brake pedal mounting bracket under the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 6641 Brake Switch (Cruise Control): Description and Operation The switch is mounted on the brake pedal mounting bracket under the instrument panel. Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged). The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal. With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low. The low voltage signal, monitored by the PCM, indicates that the brakes are not applied. When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on. Through the brake switch, current is routed to the speed control servo solenoids. The speed control solenoids (vacuum, vent and dump) are provided this current any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and current is interrupted to the solenoids. The normally open contacts are fed battery voltage. When the brakes are applied, battery voltage is supplied to the brake lamps. The Tail lamps on the Durango are mounted at the rear of the vehicle, outboard of the rear hatch and integrated into the lines of the vehicle. The tail lamp module contains a housing, lens, and three bulbs. Dual filament bulb is used for tail, stop, and turn signal operations. A separate bulb is used for back-up illumination. Tail lamp functions are controlled by the headlamp switch. Turn signal operations are controlled by the multifunction switch. Stop lamp functions are controlled by the stoplamp switch. The back-up lamps are controlled by the back-up lamp switch on the transmission. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Switch Module Mounting Screws 1.5 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6645 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6646 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6647 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6648 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheelmounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 6649 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE.FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 Nm (14 in. lbs.) torque. 4. Install airbag module. 5. Connect negative battery cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation The Vehicle Speed Sensor (VSS) is no longer used for any Dodge Truck. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Application and ID ABS Light: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Anti-lock Brake .................................................................................................................................... ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > RWAL Brake System ABS Light: Description and Operation RWAL Brake System Refer to Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > RWAL Brake System > Page 6662 ABS Light: Description and Operation 4 Wheel Antilock Brake System Refer to Antilock Brakes, Description and Operation, 4 Wheel Antilock Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up Audible Warning Device: Customer Interest Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest: > 08-26-00 > Sep > 00 > Central Timer Module - Lock Up > Page 6671 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up Audible Warning Device: All Technical Service Bulletins Central Timer Module - Lock Up NUMBER: 08-26-00 GROUP: Electrical EFFECTIVE DATE: Sept. 29, 2000 SUBJECT: Central Timer Module Electrically "Locks-Up" OVERVIEW: This bulletin involve replacing the Central Timer Module (CTM) with a revised part. MODELS: 2000 - 2001 (AB) Ram Van/Wagon 2000 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO THE ABOVE LISTED VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY (SALES CODE GXR). IN ADDITION, THIS BULLETIN APPLIES TO VEHICLES BUILT ON OR BEFORE THE FOLLOWING BUILD DATES: ^ RAM VAN/WAGONS BUILT ON OR BEFORE SEPTEMBER 14, 2000 (MDH 0914XX). ^ RAM TRUCKS BUILT AT THE WARREN TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "S") ON OR BEFORE SEPTEMBER 8, 2000 (MDH 0908XX). ^ RAM TRUCKS BUILT AT THE ST. LOUIS NORTH ASSEMBLY PLANT (11TH POSITION OF VIN = "J") ON OR BEFORE AUGUST 21, 2000 (MDH 0821XX). ^ RAM TRUCKS BUILT AT THE SALTILLO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "G") ON OR BEFORE AUGUST 31, 2000 (MDH 0831XX). ^ RAM TRUCKS BUILT AT THE LAGO ALBERTO TRUCK ASSEMBLY PLANT (11TH POSITION OF VIN = "M") ON OR BEFORE SEPTEMBER 6, 2000 (MDH 0906XX). ^ ALL 2000 MODEL DAKOTA AND DURANGO VEHICLES. SYMPTOM/CONDITION: Strong electromagnetic fields or devices that transmit signals in the 315 Mhz range may cause the Central Timer Module (CTM) to intermittently lock up. CTM lock-up may cause a variety of customer complaints including: ^ Remote Keyless Entry Malfunction ^ Interior Lights Will Not Come On ^ Intermittent Wipers Will Not Function ^ Chime Malfunction ^ Power Door Lock Malfunction ^ Remote Radio Switch Malfunction (if equipped) ^ Heated Seat Malfunction (if equipped) ^ Engine Will Not Start (if equipped with Vehicle Theft Alarm) ^ No Communication With The DRBIII (No Response from CTM) Essentially, all CTM controlled devices will not function if the CTM locks-up. Customers that do experience this condition may: - have their vehicle equipped with after-market accessories that emit strong electromagnetic signals such as high output Citizen Band (CB) radios or Two-Way radios. - be equipped with transmitting devices that operate in the 315 Mhz range such as older analog garage door openers. - live or drive near devices that emit strong electromagnetic signals such as two-way radio communication towers utilized by the military, law enforcement, etc. DIAGNOSIS: If the vehicle exhibits one or more of the conditions identified under Symptom/Condition, pull fuse 13 (power door lock fuse) for one (1) minute. Re-insert fuse 13. If the condition is no longer present, perform the Repair Procedure. If the condition still exists, further diagnosis is necessary, Refer to the appropriate Body Diagnostic Procedures Manual or the service information available in MDS2 for additional information. If the customer indicates that they may have experienced one or more of the above conditions but were able to correct the condition by removing power to the CTM (pull fuse 13 - Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-26-00 > Sep > 00 > Central Timer Module Lock Up > Page 6677 power door lock fuse or disconnecting the battery) and the condition cannot be duplicated, perform the Repair Procedure. Due to the nature of this issue, it may be difficult to re-create the customer's complaint PARTS REQUIRED REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the CTM. Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM removal procedures. 2. Install the new CTM (see Parts Required section). Refer to the appropriate Service Manual, Group 8E, Central Timer Module, or the service information available in MDS2, for information regarding CTM installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance Torque Converter Clutch Solenoid: All Technical Service Bulletins MIL ON - TCC/OD Solenoid Performance NUMBER: 21-11-00 GROUP: Transmissions EFFECTIVE DATE: October 02, 2000 SUBJECT: 46RE Transmission MIL Due To DTC P1740 - TCC or OD Solenoid Performance OVERVIEW: This bulletin involves the replacement of the transmission pressure boost valve cover plate. MODELS: 2000 - 2001 (AB) Ram Van 2000 - 2001 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2000 - 2001 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 46RE TRANSMISSION BUILT BEFORE AUGUST 01, 2000 (MDH O8O1XX). SYMPTOM/CONDITION: The customer may complain of a Malfunction Indicator Lamp (MIL) illumination. Upon further analysis, it is determined that the MIL is caused by Diagnostic Trouble Code (DTC) P1740 - Torque Converter Clutch (TCC) or Overdrive Solenoid Performance. Other than the MIL, the customer may not notice any other condition with the transmission. This condition may be caused by an intermittent and momentary TCC disengagement condition. The transmission valve body pressure boost valve cover plate has been revised with a larger size orifice hole to address this condition. DIAGNOSIS: 1. Warm the transmission to normal operating temperatures. 2. Using the DRB III(R), perform a torque converter clutch (TCC) stall test. The stall test has been revised so that the TCC remains engaged for a period of four (4) seconds. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE LEVEL 50.4 MDS2 SYSTEM CIS CD2067 OR HIGHER (AVAILABLE THE WEEK OF OCTOBER 2, 2000) IN ORDER TO PERFORM THE REVISED TORQUE CONVERTER CLUTCH STALL TEST. DO NOT USE EARLIER VERSION STALL TEST TO DETERMINE CONDITION OF THE TORQUE CONVERTER CLUTCH. 3. If the engine stalls as a result of the TCC stall test, then perform the Repair Procedure. 4. If the engine does not stall, as a result of the TCC stall test, then further diagnosis is required. The technician may want to consider the following components during their additional diagnosis: a cut or worn input shaft seals, a missing pump lock-up circuit check ball, or worn converter hub, input shaft, reaction shaft, and pump rotor. PARTS REQUIRED: REPAIR PROCEDURE: 1. Clean the pressure boost valve cover plate to remove any dirt or rust inhibitor prior to installation. The revised cover plate will have a 1.75 mm (0.069 inch) orifice hole versus a 1.22 mm (0.048 inch) orifice hole in the original plate. Make sure it is clean. 2. Using the appropriate Service Manual, Group 21 - Transmissions and Transfer Case, replace the transmission pressure boost valve cover plate p/n Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 6683 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 21-11-00 > Oct > 00 > MIL ON - TCC/OD Solenoid Performance > Page 6689 04617012. 3. Verify fluid level after warming up the transmission and cycling the shift lever several times. 4. Verify, and if required, adjust the transmission shift linkage and the transmission throttle valve cable per the appropriate Service Manual procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 6690 Audible Warning Device: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module GENERAL INFORMATION A chime warning system is standard factory-installed equipment on this model. CHIME WARNING SYSTEM The chime warning system provides an audible warning to the driver under the following conditions: ABS lamp illumination - Airbag indicator lamp illumination - Check gauges lamp illumination - Door is ajar with vehicle in motion - Driver side seat belt is not fastened with the ignition switch in the ON position - Head or park lamps are turned on with the ignition switch Off and the driver side front door open - Key is in the ignition switch with the ignition switch Off and the driver side front door open - Low fuel warning lamp illumination - less than about one-eighth tank of fuel remaining - Low washer fluid warning lamp illumination - Transmission oil temperature warning lamp illumination. Following are general descriptions of the major components in the chime warning system. Refer to the owner's manual in the vehicle glove box for more information on the features, use and operation of the chime warning system. CENTRAL TIMER MODULE Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an illuminated entry module into a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The highline version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. One of the functions and features that both versions of the CTM support is the chime warning system. The CTM contains a chime tone generator to perform the functions of the chime warning module. The CTM uses hard-wired switch inputs, internal programming, and a hard-wired chime request input from the instrument cluster circuitry to detect when a chime tone is required. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. This information covers the diagnosis and service of only the hard-wired inputs used by the CTM to determine that a chime tone should be generated. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB III scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. INSTRUMENT CLUSTER The instrument cluster is an electromechanical unit that contains integrated circuitry and internal programming to perform a variety of functions. The instrument cluster circuitry monitors hard-wired switch inputs, as well as message inputs received from other vehicle electronic modules on the Chrysler Collision Detection (CCD) data bus network. The instrument cluster uses these many inputs along with its internal programming to provide hard-wired chime tone requests to the Central Timer Module (CTM), which performs the functions of the chime warning module on this model. The instrument cluster circuitry also has a self-diagnostic capability. The only instrument cluster diagnosis found, consists of confirming the viability of the hard- wired chime request circuit between the instrument cluster circuitry and the CTM, and diagnosis of the hard-wired seat belt switch input to the instrument cluster. For diagnosis of the CCD data bus and the data bus message inputs, a DRB scan tool and the proper Diagnostic Procedures are recommended. The instrument cluster chime warning circuitry cannot be repaired and, if faulty or damaged, the instrument cluster assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 6691 DRIVER DOOR AJAR SWITCH The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. KEY-IN IGNITION SWITCH The key-in ignition switch is integral to the ignition switch, which is mounted on the right side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. HEADLAMP SWITCH The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The headlamp switch cannot be repaired and, if faulty or damaged, it must be replaced. DRIVER SEAT BELT SWITCH The driver seat belt switch is integral to the driver seat belt retractor assembly. The driver seat belt switch is normally closed, providing a ground signal to the instrument cluster when the ignition switch is in the On or Start positions. The seat belt switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch opens the seat belt switch sense circuit. The driver seat belt switch cannot be repaired and, if faulty or damaged, the entire driver seat belt and retractor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Chime Warning System Switches Replacement Audible Warning Device: Service and Repair Chime Warning System Switches Replacement Service procedures for the various hard-wired switches used in the chime warning system can be found in the Removal and Installation as follows: - Driver door ajar switch - refer to Door Switch for the door latch service procedures - Driver seat belt switch - refer to Seat Belt Buckle Switch for the seat belt retractor service procedures - Headlamp switch - refer to Headlamp Switch. - Key-in ignition switch - refer to Ignition Switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Chime Warning System Switches Replacement > Page 6694 Audible Warning Device: Service and Repair Central Timer Module Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Chime Warning System Switches Replacement > Page 6695 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Audible Warning Device Control Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Audible Warning Device Control Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6744 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6745 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 6746 information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 6750 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 6751 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions Brake Warning Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 6755 Brake Warning Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Brake Warning ..................................................................................................................................... ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service Precautions > Page 6756 Brake Warning Indicator: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Brake Warning Lamp The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the ON position and the park brake released, or comes on while driving, refer to Rear Wheel Antilock for vehicles equipped with a rear wheel anti-lock brake system, or refer to Antilock Brakes. If no brake system problem is found, the following procedure will help locate a faulty park brake switch or park brake switch sense circuit. 1. Check the fused ignition switch output (run/ start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Remove the instrument cluster. With the park brake switch wire harness connector still disconnected, check for continuity between the park brake switch sense circuit cavity of the park brake switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted park brake switch sense circuit as required. 5. Check for continuity between the park brake switch sense circuit cavities of the instrument cluster wire harness connector A and the park brake switch wire harness connector. There should be continuity. If OK, refer to Instrument Cluster Preliminary Diagnosis for further testing of the brake warning lamp and the instrument cluster circuitry. If not OK, repair the open park brake switch sense circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6781 Cigarette Lighter: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6782 Cigarette Lighter: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Cigar Lighter ........................................................................................................................................ ........................................................................ 161 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6783 Cigarette Lighter: Description and Operation A cigar lighter is standard equipment on this model. The cigar lighter is installed in the instrument panel lower bezel, which is located near the center of the instrument panel, below the radio. The cigar lighter base is secured by a snap fit within the instrument panel lower bezel. The cigar lighter knob and heating element unit, and the cigar lighter receptacle unit are available for service. These components cannot be repaired and, if faulty or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block only when the ignition switch is in the Accessory or ON positions. The knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6784 Cigarette Lighter: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Remove the cigar lighter knob and element from the cigar lighter receptacle. Check for continuity between the inside circumference of the cigar lighter receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the ON position. Check for battery voltage at the insulated contact located at the back of the cigar lighter receptacle. If OK, replace the faulty cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/accessory) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle. If not OK, repair the open fused ignition switch output (run/accessory) circuit to the junction block fuse as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6785 Cigarette Lighter: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Instrument Panel Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the protective cap from the power outlet receptacle base. Cigar Lighter And Power Outlet Remove/Install - Typical Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6786 4. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 6. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. INSTALLATION 1. Install the cigar lighter or power outlet mount into the instrument panel lower bezel. 2. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 3. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 4. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 5. Install the lower bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 Compass: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Compass Mini Trip Computer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Compass/Mini - Trip Computer Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6814 Compass: Description and Operation The compass mini-trip computer is located in the overhead console on models equipped with this option. The compass mini-trip computer units include the electronic control module, a Vacuum-Fluorescent Display (VFD), a compass sensor unit and two push button function switches. The compass mini-trip computer module contains a central processing unit and interfaces with other electronic modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The compass mini-trip computer provides several electronic functions and features. Some of the functions and features that the compass mini-trip computer module supports and/or controls, include the following display options: - Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Instant fuel economy (ECO) - shows the present fuel economy based upon the current vehicle distance and fuel used information. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the average miles-per-gallon from the last 30 gallons of fuel used. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned OFF. The ambient temperature sensor is hard wired to the compass mini-trip computer module. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CCD data bus messages. The compass mini-trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the compass mini-trip computer module and the CCD data bus. The compass mini-trip computer module cannot be repaired, and is available for service only as a unit. This unit includes the push button switches and the plastic module and display lens. If any of these components is faulty or damaged, the complete compass mini-trip computer module must be replaced. Compass While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The compass mini-trip computer only operates with the ignition switch in the ON position. When the ignition switch is turned to the ON position, all of the segments in the compass mini-trip computer VFD will be turned OFF for one second, then the display will return to the last function being displayed before the ignition was turned to the OFF position. With the ignition switch in the ON position, momentarily depressing and releasing the Step push button switch will cause the compass-mini-trip computer to change its mode of operation, and momentarily depressing and releasing the U.S./Metric push button will cause the unit to toggle between U.S. and Metric measurements. This compass mini-trip computer features several functions that can be reset. If both the Step and U.S./ Metric push buttons are depressed at the same time for more than one second with the ignition switch in the ON position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. For more information on the features and control functions of the compass mini-trip computer, see the owner's manual in the vehicle glove box. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6815 Compass: Testing and Inspection If the problem with the compass mini-trip computer module is an "OC" or "SC" in the compass/thermometer display, refer to Ambient Temperature Sensor. If the problem with the compass mini-trip computer module is an inaccurate or scrambled display, refer to Self-Diagnostic Test. If the problem with the compass mini-trip computer module is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the Chrysler Collision Detection (CCD) data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fused ignition switch output (RUN/START) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (RUN/START) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavities of the roof wire harness connector for the overhead console and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the roof wire harness connector for the overhead console. If OK, refer to Self-Diagnostic Test for further diagnosis of the compass mini-trip computer module and the CCD data bus. If not OK, repair the open fused ignition switch output (RUN/START) circuit to the junction block fuse as required. Self-Diagnostic Test A self-diagnostic test is used to determine that the compass mini-trip computer module is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the OFF position, simultaneously depress and hold the Step button and the U.S./Metric button. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons depressed until the compass mini-trip computer module enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the compass mini-trip computer module performs the following checks: a. Microprocessor compass circuit test b. Non-volatile memory read/write test c. Microprocessor ROM verification test d. CCD communications test. 4. Following completion of these tests, the compass mini-trip computer will return to normal operation or display one of two messages: "FML" or Respond to these test results as follows: a. If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. b. If the "FML" message is displayed, the compass mini4rip computer module is faulty and must be replaced. c. If the "CCD" message is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. d. If any VFD segment should fail to light during the display segment test, the compass mini-trip computer module is faulty and must be replaced. 5. If all tests are passed, or if the ignition switch is turned to the OFF position, the compass mini-trip computer module will automatically return to normal operation. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 6816 Compass: Adjustments Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and turn geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. To set the compass variance: Variance Settings 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the ON position. If the compass/temperature data is not currently being displayed, momentarily depress and release the Step push button to step through the display options until you have reached the compass/temperature display. 3. Depress both the U.S./Metric, and the Step push buttons and hold the buttons down until "VAR" appears in the display. This takes about five seconds. 4. Release both of the push buttons. "VAR" along with the current variance zone will appear in the display. 5. Momentarily depress and release the U.S./Metric push button to step through the zone numbers, until the zone number for your geographic location appears in the display. 6. Momentarily depress and release the Step push button to enter the displayed zone number into the compass unit memory. 7. Confirm that the correct directions are now indicated by the compass. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service Compass: Service and Repair Compass Calibration Service CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement compass mini-trip computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass Is calibrated manually, the variation number must also be reset. See Compass Variation Adjustment in the Service Procedures. Calibrate the compass manually as follows: 1. Turn the ignition switch to the ON position. If the compass/temperature data is not currently being displayed, momentarily depress and release the Step push button to step through the display options until you have reached the compass/temperature display. 2. Depress both the U.S./Metric and the Step push buttons. Hold the push buttons down until "CAL" appears in the display. This takes about ten seconds, and appears about five seconds after "WAR" is displayed. 3. Release both of the push buttons. 4. Drive the vehicle on a level surface, away from large metal objects and power lines, through three or more complete circles in not less than 48 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service > Page 6819 Compass: Service and Repair Compass Demagnetizing Service A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the OFF position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. Roof Demagnetizing Pattern 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Refer to Compass Variation Adjustment and Compass Calibration. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Service > Page 6820 Compass: Service and Repair Compass Mini-Trip Computer Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner. Compass Mini-Trip Computer Remove/Install 3. Remove the four screws that secure the compass mini-trip computer module to the overhead console housing. 4. Pull the compass mini-trip computer module away from the overhead console far enough to access the wire harness connectors. 5. Disengage the overhead console wire harness connector from the mount on the compass mini-trip computer module housing by pushing the connector firmly toward the left side of the overhead console housing. 6. Disconnect the overhead console wire harness connector from the compass mini-trip computer module connector receptacle. 7. Remove the compass mini-trip computer module from the overhead console housing. INSTALLATION 1. Position the compass mini-trip computer module onto the overhead console housing. 2. Reconnect the overhead console wire harness connector to the compass mini-trip computer module connector receptacle. 3. Engage the overhead console wire harness connector onto the mount on the compass mini-trip computer module housing by aligning the channels on the connector with the tab on the mount and pushing the connector firmly toward the right side of the overhead console housing. 4. Install and tighten the four screws that secure the compass mini-trip computer module to the overhead console housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the overhead console onto the headliner. 6. Reconnect the battery negative cable. NOTE: If a new compass mini-trip computer has been installed, the compass will have to be calibrated and the variance set. Refer to Compass Variation Adjustment and Compass Calibration in the Service Procedures. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6825 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6829 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6830 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 6831 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6835 Fuel Gauge Sender: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6836 Fuel Gauge Sender: Description and Operation FUEL GAUGE SENDING UNIT Fig. 2 - Fuel Pump Module Components (Typical Pump Module Shown) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6837 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6838 Fuel Gauge Sender: Service and Repair Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 27). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 4-way electrical connector (Fig. 27). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6839 Fig. 28 - Fuel Gauge Sending Unit Lock Tab/Tracks 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 28). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6844 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service Precautions Instrument Panel Bulb: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service Precautions > Page 6848 Instrument Panel Bulb: Description and Operation The cluster illumination lamps are hard wired in the instrument cluster. When the park or head lamps are turned on, the cluster illumination lamps light. Illumination brightness is adjusted by rotating the headlamp switch panel lamps dimmer thumbwheel (down to dim, up to brighten). The instrument cluster illumination lamps receive battery feed from the panel dimmer circuitry in the headlamp switch through a fuse in the junction block. The instrument cluster electronic circuitry also monitors the cluster illumination lamp dimming level whenever the park or head lamps are turned on. The instrument cluster electronic circuitry responds by adjusting the dimming level of the instrument cluster Vacuum Fluorescent Display(s) (VFD), and sending dimming level messages over the Chrysler Collision Detection (CCD) data bus network. All VFDs are illuminated at full brightness for improved daylight visibility whenever the park lamps or headlamps are turned OFF. Each of the cluster illumination lamps is located on the instrument cluster circuit board. Each cluster illumination lamp has a replaceable bulb and bulb holder. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service Precautions > Page 6849 Instrument Panel Bulb: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Cluster Illumination Lamp The diagnosis found here addresses an inoperative instrument cluster illumination lamp condition. If the problem being diagnosed includes inoperative exterior lighting controlled by the headlamp switch, that system needs to be repaired first. If the exterior lamps controlled by the headlamp switch are inoperative, refer to Headlamp Diagnosis. If no exterior lighting system problems are found, the following procedure will help locate a short or open in the cluster illumination lamp circuit. If the problem being diagnosed involves a lack of dimming control for the odometer/trip odometer Vacuum Fluorescent Display (VFD), but all of the other cluster illumination lamps can be dimmed, repair the open headlamp switch output circuit input to the instrument cluster. 1. Check the panel lamps dimmer fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the panel lamps dimmer fuse in the junction block. Rotate the panel lamps dimmer thumbwheel downward while observing the test voltmeter. The reading should go from battery voltage to zero volts. If OK, go to Step 3. If not OK, repair the open panel lamps dimmer switch signal circuit to the headlamp switch as required. If the circuit tests OK, refer to Headlamp Diagnosis 3. Disconnect and isolate the battery negative cable. Remove the instrument cluster. Turn the headlamp switch OFF. Remove the panel lamps dimmer fuse from the junction block. Probe the fused panel lamps dimmer switch signal circuit cavity of the instrument cluster wire harness connector B. Check for continuity to a good ground. There Should be no continuity. If OK, go to Step 4. If not OK, repair the shorted fused panel lamps dimmer switch signal circuit as required. 4. Install the panel lamps dimmer fuse in the junction block. Connect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer switch signal circuit cavity of the instrument cluster wire harness connector B. If OK, replace the faulty cluster illumination lamp bulb(s) and bulb holder(s). If not OK, repair the open fused panel lamps dimmer switch signal circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Application and ID Low Fuel Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Low Fuel .............................................................................................................................................. ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Application and ID Maintenance Required Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Maintenance Required ........................................................................................................................ ..................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Application and ID Malfunction Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Check Engine ...................................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 6862 Oil Change Reminder Lamp: Service and Repair This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Engine Oil Pressure ............................................................................................................................. .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Module Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information under Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Whenever a reference exists to another sheet or figure, find the corresponding diagram in Complete Body and Chassis Diagrams, using the Group Index. The reference number for the subsequent diagram will match a listed group shown. See: Diagrams/Electrical Diagrams How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Terminology This is a list of terms and definitions used in the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector and Terminal Replacement CONNECTOR AND TERMINAL REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove 6 inches of tape from the harness. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Stagger Cutting Wires 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 9. Spread the strands of the wire apart on each part of the exposed wires. 10. Push the two ends of wire together until the strands of wire are close to the Insulation. 11. Twist the wires together. 12. Solder the connection together using rosin core type solder only. Do not use acid core solder. 13. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery, and test all affected systems. Connector Replacement CONNECTOR REPLACEMENT 1. Disconnect battery. 2. Disconnect the connector that is to be repaired from its mating half/component Connector Locking Wedge Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps four through six for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pinout identification, refer to the wiring diagrams. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect connector to its mating half/component. 10. Connect battery and test all affected systems. Diode Replacement REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Disconnect battery. 2. Disconnect the connector being repaired from its mating half/component. Fig.16 Connector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required (Fig. 16). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Fig.17 Terminal Removal Fig.18 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 17) (Fig. 18). 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. INSTALLATION 1. Select a wire from the terminal repair assembly that best matches the color wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness a. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. b. Spread the strands of the wire apart on each part of the exposed wires. c. Push the two ends of wire together until the strands of wire are close to the insulation. d. Twist the wires together. e. Solder the connection together using rosin core type solder only. Do not use acid core solder. f. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Terminal/Connector Repair-Augat Connectors REMOVAL Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Fig.8 Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals (Fig. 8). Fig.9 Using Special Tool 6932 4. Using special tool 6932, push the terminal to remove it from the connector (Fig. 9). 5. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. When the connector is re-assembled, the locking tab must be placed in the locked position to prevent terminal push out. 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Terminal/Connector Repair-Molex Connectors REMOVAL 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Fig.10 Molex Connector Repair 3. Insert special tool 6742 into the terminal end of the connector (Fig. 10). Fig.11 Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal (Fig. 11). 5. Pull on the wire to remove it from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 4. Connect connector to its mating half/component. 5. Connect battery and test all affected systems. Terminal/Connector Repair-Thomas and Betts Connectors REMOVAL 1. Disconnect battery. 2. Disconnect the connector from its mating half/component. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Fig.12 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector (Fig. 12). Fig.13 Removing Wire Terminal 4. Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). 5. Grasp the wire and tool 6934, then slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal as necessary. INSTALLATION 1. Reset the terminal locking tang. 2. Insert the removed wire in the same cavity on the repair connector. 3. Repeat steps for each wire in the connector, being sure that all wires are fully seated into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Fig.14 Single Lock Tab 4. Push in the single lock tab on the side of the connector (Fig. 14). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Wiring Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 4. Spread the strands of the wire apart on each part of the exposed wire (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core type solder only. Do not use acid core solder. 8. Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Audible Warning Device Control Module: Connector Views Central Timer Module - C1 Central Timer Module - C2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Audible Warning Device Control Module: Electrical Diagrams Base 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 8w-45-4 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 8w-45-11 - Base Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 8w-45-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 8w-45-3 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 8w-45-5 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 8w-45-6 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 8w-45-7 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 8w-45-8 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 8w-45-9 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 8w-45-10 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 8w-45-12 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 8w-45-13 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 8w-45-14 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 8w-45-15 - Premium Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 8w-45-16 NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 Central Timer Module System Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6918 Audible Warning Device Control Module: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6919 Audible Warning Device Control Module: Description and Operation For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The base CTM also uses inputs from the door ajar switches, the headlamp switch and the key-in ignition switch to control the output to the dome lamp circuits, which allows the base CTM to provide load shedding to help protect the battery from becoming discharged. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. For diagnosis of the base version of the CTM, refer to Central Timer Module. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. See Wiper System for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch when the driver door is open if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A programmable driver door unlock feature. The driver door unlock feature allows one press of the RKE transmitter Unlock button to unlock just the driver door and a second press within five seconds to unlock all doors and the liftgate. If disabled, one press of the RKE transmitter Unlock button will unlock all doors and the liftgate. - A panic mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. - A central locking feature. Central locking allows all the doors and the liftgate to be locked when a key is used in either front door lock cylinder to lock either front door. Similarly, central locking will also unlock all the doors and the liftgate when the key is rapidly cycled twice to the unlock position in either front door lock cylinder. This feature uses inputs from the two door lock cylinder switches, which are components of the Vehicle Theft Security System (VTSS). - An enhanced accident response feature will unlock all doors and the liftgate, then prevent the power door lock system from locking the doors and liftgate for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors and the liftgate after the vehicle reaches a speed of about 24 kilometers-per- hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the passenger side end of the instrument panel, outboard of the instrument panel glove box opening. The programmable features of the CTM can be enabled or disabled using the DRBIII scan tool as described in the proper Diagnostic Procedures. These features can also be enabled/disabled using the customer programmable feature. See the owner's manual in the vehicle glove box for more Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 6920 information on the customer programmable feature. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRBIII scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Some of the functions and features that the CTM supports or controls include: - Chimes for the following conditions: - Headlamps on with ignition off and driver door open warning - Key in ignition with ignition off and driver door open warning - ABS lamp warning (if the vehicle is so equipped) - Airbag lamp warning - Check gauges lamp warning - Door ajar lamp warning - Low fuel lamp warning - Low washer fluid lamp warning - Seat belt reminder lamp warning - Transmission oil temperature lamp warning (automatic transmission) - Central locking - Courtesy lamp defeat - Courtesy lamp time-out (high-line only) - Intermittent wipe control - Enhanced accident response (high-line only) - Horn chirp upon door lock with RKE (customer programmable) (high-line only) - Illuminated entry (high-line only) - Power door lock control (high-line only) - Power lock inhibit (high-line only) - Remote Keyless Entry (RKE) (high-line only) - Remote radio switches (high-line only) - Rolling door locks (customer programmable) (high-line only) - Speed sensitive intermittent wipe (high-line only) - Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) - Wipe after wash (high-line only). The high-line Central Timer Module (CTM) can also control some features of the audio system when the vehicle is equipped with the optional RAZ radio receiver and remote radio switches. A high-line CTM is used on high-line versions of this vehicle. The CTM combines the functions of a chime/buzzer module, an intermittent wipe module, an illuminated entry module, a remote keyless entry module, and a vehicle theft security system module in a single unit. The high-line CTM also controls and integrates many of the additional electronic functions and features included on models with this option. The RAZ radio receiver with a remote radio switch option is one of the features that the CTM controls. The CTM is programmed to send switch status messages over the Chrysler Collision Detection (CCD) data bus to control the volume, seek, and pre-set station advance functions of the RAZ radio receiver. The CTM monitors the status of the remote radio switches located on the steering wheel through a hard wired circuit. The CTM then sends the proper switch status messages to the radio receiver. The electronic circuitry within the radio receiver responds to the switch status messages it receives by adjusting the radio settings as requested. Refer to Remote Radio Switch for more information on this component. In addition, radio receivers connected to the CCD data bus have several audio system functions that can be diagnosed using a DRB scan tool. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 1 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB III scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the problem being diagnosed involves only the RKE horn chirp feature, see Relays in the Diagnosis and Testing to test the horn relay before testing the CTM. If the relay checks OK; or if the problem being diagnosed involves the rolling door locks, door lock inhibit, central locking or enhanced accident response features, further diagnosis of the CTM should be performed using a DRB III scan tool as described in the proper Diagnostic Procedures. If the problem being diagnosed involves only the RKE driver unlock feature, be certain that the feature is enabled using a DRBIII scan tool and the proper Diagnostic Procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter twice within five seconds. If OK, see Power Lock Motor. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Audible Warning Device Control Module: Testing and Inspection "Low Line" Central Timer Module (Chime) Test 2 For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module Before testing the Central Timer Module (CTM) for an inoperative chime function, be sure to test the hard-wired switch and instrument cluster chime request circuits as described. NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool and the proper Diagnostic Procedures. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the CTM from its mounting bracket to access the CTM wire harness connectors. Refer to Central Timer Module in the Removal and Installation for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the module for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. On the high-line version of the CTM, repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (RUN/START) circuit cavity of the 14-way CTM wire harness connector. On the highline version of the CTM, repeat the check at the fused ignition switch output (RUN/ACCESSORY) circuit cavity of the 18-way CTM wire harness connector. If OK, replace the faulty CTM. If not OK, repair the open circuit from the CTM to the junction block as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 6924 Audible Warning Device Control Module: Service and Repair Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. Outboard Glove Box Opening Bracket Remove/Install 3. Remove the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection > Page 6925 Central Timer Module Remove/Install 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. 5. Remove the bracket on the outboard side of the glove box opening from the instrument panel through the glove box opening. 6. Move the CTM and its mounting bracket into the glove box opening far enough to access and disengage the instrument panel wire harness retainer from the CTM mounting bracket. 7. Disconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) from the CTM connector receptacle(s). 8. Remove the CTM and mounting bracket unit from the instrument panel through the glove box opening. INSTALLATION 1. Position the CTM and mounting bracket unit in the instrument panel glove box opening. 2. Reconnect the instrument panel wire harness connector(s) (one connector for the base CTM, two connectors for high-line CTM) to the CTM connector receptacle(s). 3. Engage the instrument panel wire harness retainer with the hole in the CTM mounting bracket. 4. Engage the tab on the outboard end of the CTM mounting bracket in the slot in the right instrument panel end bracket. 5. Working through the instrument panel glove box opening, position the outboard glove box opening bracket to the CTM mounting bracket. 6. Install and tighten the two screws that secure the Central Timer Module (CTM) mounting bracket to the bracket on the outboard side of instrument panel glove box opening. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Install and tighten the three screws that secure the bracket on the outboard side of the glove box opening to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 8. Install the glove box onto the instrument panel. 9. Reconnect the battery negative cable. NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Application and ID Seat Belt Reminder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Fasten Seat Belts ................................................................................................................................ ..................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6933 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6934 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 6935 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located in top of fuel tank. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6939 Fuel Gauge Sender: Service Precautions WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6940 Fuel Gauge Sender: Description and Operation FUEL GAUGE SENDING UNIT Fig. 2 - Fuel Pump Module Components (Typical Pump Module Shown) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. Fuel Gauge Operation A constant current source of about 32 mA is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). The resistor track is used to vary the voltage depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e. having all of the sending units electrical connectors connected). Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. OBD II Emission Monitor Requirements The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6941 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. To test the gauge sending unit only, it must be removed from vehicle. The unit is part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in UP position, resistance should be 20 ohms ± 6 ohms. With float in DOWN position, resistance should be 220 ohms ± 6 ohms. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6942 Fuel Gauge Sender: Service and Repair Fig. 27 - Fuel Gauge Sending Unit Location - Typical Module The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module (Fig. 27). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 4-way electrical connector (Fig. 27). 4. Disconnect 2 sending unit wires at 4-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 4-way connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6943 Fig. 28 - Fuel Gauge Sending Unit Lock Tab/Tracks 5. The sending unit is retained to pump module with a small lock tab and notch (Fig. 28). Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 4-way connector and install locking collar. 4. Connect 4-way electrical connector to module. 5. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 6. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair GEARSHIFT INDICATOR REMOVAL The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Fig. 13 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing (Fig. 13). 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Fig. 14 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column (Fig. 14). 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Page 6947 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. INSTALLATION The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column (Fig. 14). 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Application and ID Temperature Warning Lamp/Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Temperature Indicator ......................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service Precautions Transmission Shift Position Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service Precautions > Page 6954 Transmission Shift Position Indicator Lamp: Description and Operation An automatic transmission gear selector indicator is standard factory-installed equipment in this model, when it is also equipped with an optional automatic transmission. Two types of gear selector indicators are used, mechanical or electronic. Either gear selector indicator gives an indication of the transmission gear that has been selected with the automatic transmission gear selector lever. If the vehicle is equipped with the optional 45RFE automatic transmission, the instrument cluster contains an integral electronic gear selector indicator. All other automatic transmission types use the mechanical gear selector indicator. Diagnosis of the electronic gear selector indicator should be performed using a DRB III scan tool and the proper Diagnostic Procedures. The electronic gear selector indicator cannot be adjusted or repaired. If faulty or damaged, the instrument cluster unit must be replaced. The mechanical gear selector indicator housing is mounted to the rear of the instrument cluster housing. The mechanical gear selector indicator pointer is easily visible through an opening provided in the front of the instrument cluster mask, and is also lighted by the cluster illumination lamps for visibility at night. This information covers only the removal and installation of the mechanical gear selector indicator from the instrument cluster. The electronic gear selector indicator uses a digital Vacuum Fluorescent Display (VFD) to indicate the gear selector position. The electronic gear selector indicator is controlled by messages received by the instrument cluster circuitry from the electronic Transmission Control Module (TCM) over the CCD data bus network. The mechanical gear selector indicator has a spring-loaded pointer that is mechanically actuated by a cable connected to the gear selector indicator driver lever of the gear selector lever mechanism on the steering column. When the gear selector lever is moved the indicator driver lever moves, which actuates the spring-loaded pointer through the mechanical actuator cable. An adjuster mounted on the steering column housing provides a mechanical means of calibrating the gear selector indicator mechanism. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service Precautions > Page 6955 Transmission Shift Position Indicator Lamp: Service and Repair The following service procedures apply only to the mechanical gear selector indicator. The electronic gear selector indicator is integral to the instrument cluster and can only be serviced by replacement of the instrument cluster unit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster from the instrument panel. Gear Selector Indicator Remove/Install 3. Remove the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. 4. Remove the gear selector indicator mechanism from the back of the instrument cluster housing. 5. Remove the steering column opening cover from the instrument panel. Gear Selector Indicator Cable Remove/Install 6. Disengage the loop end of the gear selector indicator cable from the lever on the left side of the steering column. 7. Squeeze the sides of the plastic adjuster and bracket unit to disengage the tabs that secure it to the sides of the steering column window. 8. Remove the gear selector indicator mechanism and cable unit from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service Precautions > Page 6956 INSTALLATION 1. Position the gear selector indicator mechanism and cable unit to the instrument panel. 2. Squeeze the sides of the plastic adjuster and bracket unit and engage the tabs that secure it with the sides of the steering column window. 3. Engage the loop end of the gear selector indicator cable onto the lever on the left side of the steering column. 4. Position the gear selector indicator mechanism onto the back of the instrument cluster housing. 5. Install and tighten the two screws that secure the gear selector indicator mechanism to the back of the instrument cluster housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 6. Install the instrument cluster onto the instrument panel. 7. Check the gear selector indicator for proper calibration. If adjustment is needed, refer to Steering Column. 8. Install the steering column opening cover onto the instrument panel. 9. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, brake, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail Brake Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws attaching lamp to liftgate opening. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair Tail/Brake/Turn Signal/Back-Up Lamp Bulb Replacement REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, brake, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail Brake Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws attaching lamp to liftgate opening. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6969 Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch Brake Light Switch: Description and Operation Base Brake System Stop Lamp Switch Refer to Brakes and Traction Control, Brakes, Description and Operation, Brake System Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch > Page 6972 Brake Light Switch: Description and Operation RWAL System Brake Lamp Switch Refer to Brakes and Traction Control, Brakes, Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6973 Brake Light Switch: Testing and Inspection Refer to Brakes and Traction Control, Brakes, Testing and Inspection, Procedures, Base Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6974 Brake Light Switch: Service and Repair REMOVAL Fig. 15 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp Bulb Replacement Cargo Lamp: Service and Repair Liftgate/Cargo Lamp Bulb Replacement REMOVAL 1. Remove liftgate/cargo lamp from liftgate. 2. Using a small flat blade, pry lamp lens from lamp. 3. Remove bulb from lamp. INSTALLATION 1. Install in bulb in lamp. 2. Install lamp lens on lamp. 3. Install liftgate/cargo lamp in liftgate. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Liftgate/Cargo Lamp Bulb Replacement > Page 6979 Cargo Lamp: Service and Repair Liftgate/Cargo Lamp Replacement REMOVAL 1. Using a small flat blade, carefully pry the outward edge of the liftgate/cargo lamp from trim panel. 2. Release the locking tab on the lamp harness connector and disconnect the harness connector from the lamp. Liftgate/Cargo Lamp 3. Separate the lamp from the liftgate. INSTALLATION 1. Connect the harness connector to the lamp. 2. Position the lamp in the liftgate and press inward to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Remove CHMSL from liftgate. 2. Turn bulb socket 1/4 turn counterclockwise. 3. Separate socket from lamp. 4. Grasp bulb and pull from socket. INSTALLATION 1. Position bulb in socket and press into place. 2. Position socket in lamp. 3. Turn bulb socket 1/4 turn clockwise. 4. Install CHMSL. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Application and ID Ash Tray Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Ash Receiver ....................................................................................................................................... ......................................................................... 161 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service Precautions Glove Box Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service Precautions > Page 6991 Glove Box Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Glove Compartment ............................................................................................................................ ......................................................................... 194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service Precautions > Page 6992 Glove Box Lamp: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service Precautions Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service Precautions > Page 6996 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7001 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb Replacement Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement REMOVAL 1. Using a small flat blade, pry the left side (driver's side) of the lamp lens downward. 2. Pull bulb from lamp. INSTALLATION 1. Install bulb in lamp. 2. Position lens on lamp and snap into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb Replacement > Page 7007 Dome Lamp Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb Replacement REMOVAL Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7011 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7012 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7013 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Disengage fog lamp harness connector. Fog Lamp Bulb 2. Rotate bulb socket a 1/4 turn counterclockwise and pull from lamp to separate. 3. Grasp bulb and pull from lamp. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb in lamp, push to.seat and rotate a 1/4 turn clockwise. 2. Connect fog lamp harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7021 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7022 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7023 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations 8w-11-2 The combination flasher is located in the relay and fuse block which is located on the back of the junction block near the dash panel under the left end of the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7028 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7029 Hazard Warning Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7030 Hazard Warning Flasher: Description and Operation The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configuration or footprint, the internal circuitry is much different. The combination flasher does not use standard ISO-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. Because of the active electronic elements within the combination flasher it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty, test the turn signal system and hazard warning system circuits as described. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher has five blade-type terminals intended for the following inputs and outputs: fused B(+), fused ignition switch output, ground, turn signal circuit, and hazard warning circuit. Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The combination flasher is located in the relay and fuse block which is located on the back of the junction block near the dash panel under the left end of the instrument panel. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. Combination Flasher - Typical The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning circuit of the multifunction switch. When the hazard warning switch is turned on, the "hazard on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative- Positive (PNP) transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned OFF. Likewise, pin 8 of the IC receives a sense voltage from the turn signal circuits of the multi-function switch. When the left or right turn signal switch is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal switch is turned OFF. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7031 Hazard Warning Flasher: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Combination Flasher Remove/Install 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Refer to Fuse/Fuse Block. 5. Remove the combination flasher from the relay and fuse block. INSTALLATION 1. Refer to Fuse/Fuse Block 2. Position the combination flasher in the proper receptacle in the relay and fuse block. 3. Align the combination flasher terminals with the terminal cavities in the relay and fuse block receptacle. 4. Push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the relay and fuse block receptacle. 5. Install the steering column opening cover onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Indicator > Component Information > Testing and Inspection Hazard Warning Indicator: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7038 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7039 Hazard Warning Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multi-function switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning off), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning on), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7040 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7041 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 7042 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Open hood. 2. Remove headlamp assembly. 3. Remove the retaining ring holding bulb to headlamp. Headlamp Bulb 4. Pull bulb socket from headlamp. 5. Grasp bulb and pull from socket. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb into socket and push into place. 2. Position bulb socket in headlamp. 3. Install retaining ring holding bulb to headlamp. 4. Install headlamp assembly. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center Headlamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7050 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7051 Headlamp Relay: Diagrams Power Distribution Center Headlamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7052 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7053 Headlamp Relay: Description and Operation The headlamp (or security) 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7054 Headlamp Relay: Testing and Inspection The headlamp (or security) relay is located in the Power Distribution Center (PDC) in the engine compartment. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. The driver unlock relay is located in the relay and fuse block on the back of the JB underneath the left end of the instrument panel in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. To test the relay circuits, refer to the circuit descriptions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Terminals Remove the relay from the PDC, JB or the relay and fuse block 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, test the relay circuits. If not OK, replace the faulty relay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7055 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp 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 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7059 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7060 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The headlamp switch controls the parking lamps and the headlamps. A separate switch in the module controls the interior lamps, and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7061 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the headlamp switch from the instrument panel. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors.. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the OFF position, and continuity with the switch in the park or head lamps ON position. If OK, see Central Timer Module. If not OK, replace the faulty headlamp switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 7062 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions Hi-Beam Indicator Lamp: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions > Page 7066 Hi-Beam Indicator Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application High Beam ........................................................................................................................................... ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Service Precautions > Page 7067 Hi-Beam Indicator Lamp: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Headlamp High Beam Indicator Lamp The diagnosis found here addresses an inoperative headlamp high beam indicator lamp condition, If the problem being diagnosed is related to inoperative headlamp high beams, refer to Headlamp Diagnosis. If no headlamp system problems are found, the following procedure will help locate an open in the high beam indicator lamp circuit. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable. Turn the headlamps on and select the high beams with the multi-function switch stalk. Check for battery voltage at the high beam indicator driver circuit cavity of the instrument cluster wire harness connector B. If OK, replace the faulty bulb. If not OK, repair the open high beam indicator driver circuit to the headlamp dimmer (multi-function) switch as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-12-2 Horn Relay is located in the Junction Block (JB). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7072 Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7073 Horn Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7074 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7075 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7076 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. The horn 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM ) grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. See the fuse and relay layout label on the inside of the fuse access panel for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7077 Horn Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Horn Relay Remove/Install 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 7081 Horn Switch: Description and Operation Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 7082 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. If not OK, refer to Steering Column. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service Precautions > Page 7083 Horn Switch: Service and Repair Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. See: Restraint Systems/Air Bag Systems/Air Bag Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Application and ID Key Cylinder Lamp: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Ignition Key .......................................................................................................................................... ......................................................................... 53 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL 1. Remove license plate lamp from rear bumper. License Plate Lamp Bulb 2. Remove bulb socket from lamp. 3. Pull bulb from socket. INSTALLATION 1. Push bulb in socket. 2. Install bulb socket in lamp. 3. Install license plate lamp in rear bumper. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Replacement Map Light Bulb: Service and Repair Overhead Console Reading Lamp Bulb Replacement REMOVAL 1. Using a small flat blade, carefully pry forward edge of reading lamp lens downward from lamp. 2. Disengage lamp lens from pivots on overhead console. 3. Rotate bulb holder and pull bulb from lamp. INSTALLATION 1. Position bulb in lamp and rotate to secure. Reading Lamp Lens 2. Position lamp lens on overhead console. Ensure contact tab on lamp lens is aligned with lamp switch. 3. Carefully press lamp lens onto pivots. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Replacement > Page 7096 Map Light Bulb: Service and Repair 2nd Seat Dome/Reading Lamp Bulb Replacement REMOVAL Lamp Lens 1. Using a small flat blade, pry the center rearward edge of the dome/reading lamp lens downward from lamp. Dome/Reading Lamp Bulb 2. Pull bulb from socket. INSTALLATION 1. Position bulb in lamp. 2. Push the lamp lens up into the lamp to secure. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Headlamp Bulb 2. Remove side marker lamp socket from back of lamp. 3. Pull side marker lamp bulb from socket. INSTALLATION 1. Install side marker lamp bulb in socket. 2. Install side marker lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Daytime Running Lamp Module The Daytime Running Lamp Module is located on the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7109 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Fog Lamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7113 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7114 Fog/Driving Lamp Relay: Diagrams Power Distribution Center Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7115 Fog Lamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Power Distribution Center Headlamp Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7119 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7120 Headlamp Relay: Diagrams Power Distribution Center Headlamp Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7121 Headlamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7122 Headlamp Relay: Description and Operation The headlamp (or security) 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the Power Distribution Center (PDC), behind the battery on the left side of the engine compartment. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7123 Headlamp Relay: Testing and Inspection The headlamp (or security) relay is located in the Power Distribution Center (PDC) in the engine compartment. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. The driver unlock relay is located in the relay and fuse block on the back of the JB underneath the left end of the instrument panel in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. To test the relay circuits, refer to the circuit descriptions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Terminals Remove the relay from the PDC, JB or the relay and fuse block 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, test the relay circuits. If not OK, replace the faulty relay. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7124 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp 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 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations 8w-12-2 Horn Relay is located in the Junction Block (JB). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7128 Junction Block (JB) Junction Block is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7129 Horn Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7130 8w-12-4 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7131 Horn Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7132 Horn Relay: Description and Operation The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. See the fuse and relay layout label affixed to the inside surface of the fuse access panel for horn relay identification and location. The horn relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The horn relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. The horn 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch or the high-line Central Timer Module (CTM ) grounds the relay coil. The horn relay is located in the Junction Block (JB), on the left end of the instrument panel in the passenger compartment. See the fuse and relay layout label on the inside of the fuse access panel for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the JB until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7133 Horn Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Horn Relay Remove/Install 2. Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrument panel. 3. See the fuse and relay layout label affixed to the inside of the fuse access panel for horn relay identification and location. 4. Grasp the horn relay firmly and pull it straight out from the JB. INSTALLATION 1. See the fuse and relay layout label affixed to the inside of the fuse access panel for the proper horn relay location. 2. Position the horn relay in the proper receptacle in the JB. 3. Align the horn relay terminals with the terminal cavities in the JB receptacle. 4. Push in firmly on the horn relay until the terminals are fully seated in the terminal cavities in the JB receptacle. 5. Insert the tabs on the forward edge of the fuse access panel in the notches on the forward edge of the instrument panel fuse access panel opening. 6. Press the rear edge of the fuse access panel in toward the instrument panel until the panel snaps back into place 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7137 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7138 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7143 Brake Lamp Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch Brake Light Switch: Description and Operation Base Brake System Stop Lamp Switch Refer to Brakes and Traction Control, Brakes, Description and Operation, Brake System Components for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Base Brake System Stop Lamp Switch > Page 7146 Brake Light Switch: Description and Operation RWAL System Brake Lamp Switch Refer to Brakes and Traction Control, Brakes, Antilock Brakes, Description and Operation, RWAL Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7147 Brake Light Switch: Testing and Inspection Refer to Brakes and Traction Control, Brakes, Testing and Inspection, Procedures, Base Brake Components and Systems for information. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7148 Brake Light Switch: Service and Repair REMOVAL Fig. 15 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30° to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Press and hold brake pedal down. 2. Align tab on new switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30° to lock it in place. 3. Connect harness wires to switch. 4. Release brake pedal. 5. Move the release lever on the switch to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams Door Switch: Diagrams Driver Door Ajar Switch Passenger Door Ajar Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7152 Door Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7153 Door Switch: Description and Operation The driver door ajar switch is integral to the driver side front door latch. The switch closes a path to ground for the Central Timer Module (CTM) when the driver door is opened, and opens the ground path when the driver door is closed. The driver door ajar switch cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 7154 Door Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the headlamp switch knob counterclockwise to ensure that the dome lamps are not switched OFF. Open the driver door and note whether the interior lamps light. They should light. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, go to Step 2. 2. Disconnect and isolate the battery negative cable. Unplug the driver door latch wire harness connector. Check for continuity between the ground circuit cavity in the body half of the driver door latch wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the circuit to ground as required. 3. Check for continuity between the driver door ajar switch ground circuit terminal and the driver door ajar switch sense circuit terminal of the driver door latch wire harness connector. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 4. If not OK, replace the faulty latch. 4. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Unplug the 14-way CTM wire harness connector. Check for continuity between the driver door ajar switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the driver door ajar switch sense circuit cavities of the 14-way CTM wire harness connector and the driver door latch wire harness connector. There should be continuity. If OK, see Key-In Ignition Switch and/or Headlamp Switch. If not OK, repair the open circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service Precautions Glove Box Lamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service Precautions > Page 7158 Glove Box Lamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. 3. Reach through the glove box opening and behind the glove box opening upper reinforcement in the instrument panel to access and depress the retaining latches on the top and bottom of the glove box lamp and switch housing. Glove Box Lamp And Switch Remove/Install 4. While holding the retaining latches depressed, push the glove box lamp and switch out through the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Pull the glove box lamp and switch out from the mounting hole far enough to access the wire harness connector. 6. Disconnect the instrument panel wire harness connector from the glove box lamp and switch connector receptacle. 7. Remove the glove box lamp and switch from the instrument panel. INSTALLATION 1. Position the glove box lamp and switch to the instrument panel. 2. Reconnect the instrument panel wire harness connector to the glove box lamp and switch connector receptacle. 3. Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upper reinforcement. 4. Align the glove box lamp and switch housing with the mounting hole in the instrument panel glove box opening upper reinforcement. 5. Push the glove box lamp and switch into the mounting hole in the instrument panel glove box opening upper reinforcement until the retaining latches are fully engaged. 6. Close the glove box. 7. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7162 Hazard Warning Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7163 Hazard Warning Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multi-function switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning off), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning on), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7164 Hazard Warning Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7165 Hazard Warning Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 7166 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The headlamp switch is located in the instrument panel, outboard of the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7170 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7171 Headlamp Switch: Description and Operation The headlamp switch is located in the instrument panel, outboard of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the park or head lamps are ON and the driver door ajar switch is closed (driver door is open). The headlamp switch opens the ground path when the headlamp switch is turned OFF. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The headlamp switch controls the parking lamps and the headlamps. A separate switch in the module controls the interior lamps, and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps. The headlamp switch has an OFF position, a parking lamp position, and a headlamp ON position. High beams are controlled by the multifunction switch on the steering column. The headlamp switch cannot be repaired. It must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7172 Headlamp Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the headlamp switch from the instrument panel. Unplug the headlamp switch wire harness connectors. Check for continuity between the driver door ajar switch sense circuit cavity of the headlamp switch wire harness connector and a good ground. There should be continuity with the driver door open, and no continuity with the driver door closed. If OK, go to Step 2. If not OK, repair the circuit to the driver door ajar switch as required. 2. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors.. Unplug the 14-way CTM wire harness connector. Remove the key from the ignition lock cylinder. Check for continuity between the key-in ignition switch sense circuit cavity of the 14-way CTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the key-in ignition switch sense circuit cavities of the 14-way CTM wire harness connector and the headlamp switch wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the driver door ajar switch sense circuit terminal and the key-in ignition switch sense circuit terminal of the headlamp switch. There should be no continuity with the switch in the OFF position, and continuity with the switch in the park or head lamps ON position. If OK, see Central Timer Module. If not OK, replace the faulty headlamp switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 7173 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. Headlamp Switch Remove/Install 3. Remove the three screws that secure the headlamp switch to the instrument panel. 4. Pull the headlamp switch away from the instrument panel far enough to access the instrument panel wire harness connectors. 5. Disconnect the two instrument panel wire harness connectors from the headlamp switch connector receptacles. 6. Remove the headlamp switch from the instrument panel. INSTALLATION 1. Position the headlamp switch to the instrument panel. 2. Reconnect the two instrument panel wire harness connectors to the headlamp switch connector receptacles. 3. Install the headlamp switch into the instrument panel. 4. Install and tighten the three screws that secure the headlamp switch to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the cluster bezel onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7177 Horn Switch: Description and Operation Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The switch consists of two plastic membranes, one that is flat and one that is slightly convex. These two membranes are secured to each other around the perimeter. Inside the switch, the centers of the facing surfaces of these membranes each has a grid made with an electrically conductive material applied to it. One of the grids is connected to a circuit that provides it with continuity to ground at all times. The grid of the other membrane is connected to the horn relay control circuit. The steering wheel and steering column must be properly grounded in order for the horn switch to function properly. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit. The completed horn switch circuit provides a ground for the control coil side of the horn relay, which activates the relay. When the horn switch is released, the resistive tension of the convex membrane separates the two electrically conductive grids and opens the switch circuit. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7178 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 3. If not OK, refer to Steering Column. 3. Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire harness connectors from the driver side airbag module. 4. Remove the horn relay from the Junction Block (JB). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted horn relay control circuit to the horn relay in the JB as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the JB. There should be continuity. If OK, go to Step 6. If not OK, repair the open horn relay control circuit to the horn relay in the JB as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 7179 Horn Switch: Service and Repair Driver Side Airbag Module Trim Cover And Horn Switch A center-blow, normally open, resistive membrane-type horn switch is secured with heat stakes to the back side of the driver side airbag module trim cover in the center of the steering wheel. The horn switch is only serviced as a part of the driver side airbag module trim cover. If the horn switch is damaged or faulty, or if the driver side airbag is deployed, the driver side airbag module trim cover and horn switch must be replaced as a unit. See: Restraint Systems/Air Bag Systems/Air Bag Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7183 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7184 Turn Signal Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7185 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7186 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7187 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair Tail/Brake/Turn Signal/Back-Up Lamp Bulb Replacement REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, brake, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail Brake Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws attaching lamp to liftgate opening. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Trailer Tow Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7195 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7196 Trailer Lighting Relay: Diagrams Power Distribution Center Trailer Tow Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation Turn Signal Cancel Cam: Description and Operation TURN SIGNAL CANCELLING CAM The turn signal cancelling cam is concealed within the steering column below the steering wheel. The turn signal cancelling cam consists of two lobes that are integral to the lower surface of the clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver side airbag module, speed control switches and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring is secured to the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancelling cam lobes rotate with the steering wheel. The turn signal cancelling cam is integral to the clockspring and cannot be repaired. If faulty or damaged, the entire clockspring assembly must be replaced. The turn signal cancelling cam has two lobes molded into the lower surface of the clockspring rotor. When the turn signals are activated by moving the multi-function switch control stalk to a detent position, a turn signal cancel actuator is extended from the inside surface of the multi-function switch housing toward the clockspring rotor. When the steering wheel is rotated during the turn, one of the two turn signal cancelling cam lobes will contact the turn signal cancel actuator, releasing the multi-function switch control stalk from its detent and cancelling the turn signal event. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7204 8w-11-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7205 Turn Signal Flasher: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7206 Turn Signal Flasher: Description and Operation The combination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher. The combination flasher contains active electronic Integrated Circuitry (IC) elements. This flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically try to compensate to keep the flash rate the same. While the combination flasher has a International Standards Organization (ISO)-type relay terminal configuration or footprint, the internal circuitry is much different. The combination flasher does not use standard ISO-relay inputs or provide ISO-relay type outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle damage may occur. Because of the active electronic elements within the combination flasher it cannot be tested with conventional automotive electrical test equipment. If the combination flasher is believed to be faulty, test the turn signal system and hazard warning system circuits as described. Then replace the combination flasher with a known good unit to confirm system operation. The combination flasher has five blade-type terminals intended for the following inputs and outputs: fused B(+), fused ignition switch output, ground, turn signal circuit, and hazard warning circuit. Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function, and ignition switched battery voltage is supplied for the turn signal function. The combination flasher is located in the relay and fuse block which is located on the back of the junction block near the dash panel under the left end of the instrument panel. The combination flasher cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. Combination Flasher - Typical The IC within the combination flasher contains the logic that controls the flasher operation and the flash rate. Pin 6 of the IC receives a sense voltage from the hazard warning circuit of the multifunction switch. When the hazard warning switch is turned on, the "hazard on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control Positive-Negative- Positive (PNP) transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the hazard warning circuit, the pin 6 "hazard on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the hazard warning switch is turned OFF. Likewise, pin 8 of the IC receives a sense voltage from the turn signal circuits of the multi-function switch. When the left or right turn signal switch is turned on, the "turn signal on sense" voltage will become low due to the circuit being grounded through the turn signal bulbs. This low voltage sense signals the IC to energize the flash control PNP transistor at a pre-calibrated flash rate or frequency. Each time the PNP transistor energizes the turn signal circuit, the pin 8 "turn signal on sense" voltage will become high and the IC signals the PNP transistor to de-energize the circuit. This cycling will continue until the right or left turn signal switch is turned OFF. A special design feature of the combination flasher allows it to "sense" that a turn signal circuit or bulb is not operating, and provide the driver an indication of the condition by flashing the remaining bulbs in the affected circuit at a higher rate (120 flashes-per-minute or higher). Conventional flashers either continue flashing at their typical rate (heavy-duty type), or discontinue flashing the affected circuit entirely (standard-duty type). During turn signal operation, the combination flasher IC compares normal battery voltage input on pin 2 with the shunt resistor voltage input on pin 7. If the IC "senses" that the voltage difference between pin 2 and pin 7 is different than the pre-calibrated value of the IC, it will increase the rate at which it signals the PNP transistor to energize the pin 1 output. Thus, the inoperative half (left or right side) of the turn signal circuit will flash faster. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7207 Turn Signal Flasher: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover from the instrument panel. Combination Flasher Remove/Install 3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the junction block. 4. Refer to Fuse/Fuse Block. 5. Remove the combination flasher from the relay and fuse block. INSTALLATION 1. Refer to Fuse/Fuse Block 2. Position the combination flasher in the proper receptacle in the relay and fuse block. 3. Align the combination flasher terminals with the terminal cavities in the relay and fuse block receptacle. 4. Push in firmly on the combination flasher until the terminals are fully seated in the terminal cavities in the relay and fuse block receptacle. 5. Install the steering column opening cover onto the instrument panel. 6. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Application and ID Turn Signal Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced. Bulb Application Front Park/Turn Signal ........................................................................................................................ ...................................................................... 3157 Tail, Brake, Turn Signal and Side Marker ............ ..................................................................................................................................................... 3057 Turn Signal .......................................................................................................................................... .................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Application and ID > Page 7211 Turn Signal Indicator: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Turn Signal Indicator Lamp The diagnosis found here addresses an inoperative turn signal indicator lamp condition. If no turn signal or hazard warning system problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster. 2. Connect the battery negative cable. Activate the hazard warning system by moving the hazard warning switch button to the ON position. Check for battery voltage at the inoperative (right or left) turn signal circuit cavity of the instrument cluster wire harness connector B. There should be a switching (ON and OFF) battery voltage signal. If OK, replace the faulty (right or left) turn signal indicator lamp bulb. If not OK, repair the open (right or left) turn signal circuit to the turn signal/hazard warning (multi-function) switch as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulbs Replacement Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulbs Replacement REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulbs Replacement > Page 7217 Turn Signal Bulb: Service and Repair Tail, Brake, Turn Signal and Back-Up Lamp Bulb Replacement REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws attaching tail, brake, turn signal and back-up lamp to liftgate opening. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail Brake Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws attaching lamp to liftgate opening. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7221 Turn Signal Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7222 Turn Signal Switch: Description and Operation Multi-Function Switch The turn signal and hazard warning switches are integral to the multi-function switch unit, which is secured to the left side of the steering column. The only visible parts of the multi-function switch are the control stalk that extends from the left side of the steering column, and the hazard warning switch push button that protrudes from the top of the steering column. The multi-function switch control stalk has both nomenclature and international control symbols on it, which identify its many functions. The hazard warning switch push button is identified with a double triangle, which is the international control symbol for hazard warning. The remainder of the multi-function switch is concealed beneath the steering column shrouds. The multi-function switch also contains circuitry for the following functions: - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the multi-function switch turn signal and hazard warning functions. However, the turn signal and hazard warning switches cannot be repaired. If these switches or any other circuit or component of the multi-function switch unit is faulty or damaged, the entire multifunction switch unit must be replaced. Hazard Warning Switch The hazard warning switch is controlled by the hazard warning switch push button. Push the switch button in to unlatch the switch and activate the hazard warning system, and push in ON the button again to latch the switch and turn the system OFF. When the hazard warning switch is latched (hazard warning OFF), the push button will be in a lowered position on the top of the steering column shroud; and, when the hazard warning switch is unlatched (hazard warning ON), the push button will be in a raised position. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7223 Turn Signal Switch: Testing and Inspection The turn signal switch and the hazard warning switch are integral to the multi-function switch. Refer to Turn Signal and Hazard Warning Systems before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the connector receptacle terminals as shown in the Multi-Function Switch Continuity chart. 3. If the turn signal switch or hazard warning switch fails any of the continuity checks, replace the faulty multi-function switch assembly as required. If the switch circuits are OK, repair the lighting circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7224 Turn Signal Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, unscrew the lever from the tilt steering column adjuster mechanism located on the left side of the column just below the multi-function switch stalk. Turn the lever counter clockwise to unscrew it from the column. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud from the steering column. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7225 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the back of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof Torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the multi-function switch away from the steering column far enough to access and remove the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. 8. Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle. 9. Remove the multi-function switch from the steering column. INSTALLATION 1. Position the multi-function switch onto the steering column. 2. Reconnect the instrument panel wire harness connector to the multi-function switch connector receptacle. 3. Install and tighten the screw that secures the instrument panel wire harness connector to the multi-function switch connector receptacle. Tighten the screw to 2 Nm (17 in. lbs.). 4. Install and tighten the two screws that secure the multi-function switch to the steering column. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the lower fixed column shroud onto the steering column. 6. Install both the upper and lower shrouds onto the steering column. 7. If the vehicle is so equipped, install the tilt steering column lever onto the left side of the steering column by screwing it into place. 8. Reconnect the battery negative cable. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Insert a small flat blade in the access slot between the lamp base and lamp lens. Underhood Lamp Lens 2. Pry the lamp lens upward and remove the lamp lens. Underhood Lamp Bulb 3. Depress the bulb terminal inward to release the bulb. INSTALLATION 1. Engage the replacement bulb wire loop to the terminal closest to the lamp base wire connector. 2. Depress the opposite terminal inward and engage the remaining bulb wire loop. 3. Position the lamp lens on the lamp base and press into place. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7235 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned On. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7236 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch pod. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty rear window switch pod. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7237 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions Rear Window Defogger Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7242 Rear Window Defogger Switch: Description and Operation The rear window defogger switch is integral to the rear window switch pod, which includes the rear wiper and washer switches. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The momentary-type rear window defogger switch provides a hard wired ground signal to the rear window defogger logic and timer circuitry, each time it is depressed. The rear window defogger timer and logic circuitry responds by energizing or de-energizing the rear window defogger relay and the amber defogger indicator lamp, which lights to indicate when the defogger system is turned On. Energizing the rear window defogger relay provides electrical current to the rear window defogger grid. The rear window switch pod cannot be repaired. If any function of the switch pod except lighting is faulty or damaged, the entire switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7243 Rear Window Defogger Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. 2. Check for continuity between the ground circuit cavity of the rear window switch pod wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 4. If not OK, repair the circuit to the Power Distribution Center (PDC) fuse as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the rear window switch pod wire harness connector. If OK, go to Step 5. If not OK, repair the circuit to the junction block fuse as required. 5. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear window switch pod. Connect the battery negative cable. Turn the ignition switch to the ON position. Back probe the rear window defogger relay output circuit cavity of the rear window switch pod wire harness connector. Depress and release the rear window defogger switch. There should be battery voltage. Depress and release the rear window defogger switch again. There should be zero volts. If OK, go to Step 6. If not OK, replace the faulty rear window switch pod. 6. Depress and release the rear window defogger switch. The rear window defogger indicator lamp should light. If the indicator lamp does not light, replace the bulb with a known good unit and test again. If the lamp is still inoperative, replace the faulty rear window switch pod. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Window Defogger Switch <--> [Heated Glass Element Switch] > Component Information > Service Precautions > Page 7244 Rear Window Defogger Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7248 Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7249 Power Window Switch: Description and Operation The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two- way power window switch mounted in a bezel on their respective door trim panels. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. The power window switch for the driver side front door has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7250 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, perform the diagnosis for Power Window System. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel. Unplug the wire harness connector from the switch unit, Power Window Switch Continuity - Driver Side Front - Quad Cab Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7251 Power Window Switch Continuity - Front and Rear Passenger Doors - Quad Cab 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, see Power Window Motor. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the ON position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications > Page 7252 Power Window Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation An automatic resetting circuit breaker in the junction block is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7257 Power Window Circuit Breaker: Testing and Inspection 1. Locate the circuit breaker in the junction block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still contact the terminals in the junction block cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. If the circuit breaker checks OK, but no power windows operate, see Power Window System. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams Passenger Door Window Motor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7261 Power Window Motor: Description and Operation WINDOW MOTOR A permanent magnet reversible motor moves the window regulator through an integral gearbox mechanism. A positive and negative battery connection to the two motor terminals will cause the motor to rotate in one direction. Reversing the current through these same two connections will cause the motor to rotate in the opposite direction. In addition, each power window motor is equipped with an integral self-resetting circuit breaker to protect the motor from overloads. The power window motor and gearbox assembly cannot be repaired and, if faulty or damaged, the entire power window regulator assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7262 Power Window Motor: Testing and Inspection Before you proceed with this diagnosis, confirm proper switch operation. 1. Disconnect and isolate the battery negative cable. Remove the trim panel from the door with the inoperative power window. 2. Unplug the power window motor wire harness connector. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the connections across the motor terminals to check the operation in the other direction. Remember, if the window is in the full up or full down position, the motor will not operate in that direction by design. If OK, repair the circuits from the power window motor to the power window switch as required. If not OK, replace the faulty motor. 3. If the motor operates in both directions, check the operation of the window glass and lift mechanism through its complete up and down travel. There should be no binding or sticking of the window glass or lift mechanism through the entire travel range. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7263 Power Window Motor: Service and Repair REMOVAL AND INSTALLATION The power window motor and mechanism is integral to the power window regulator unit. If the power window motor or mechanism is faulty or damaged, the entire power window regulator unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Power Window Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7267 Driver Power Window/Door Lock Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7268 Power Window Switch: Description and Operation The power windows are controlled by four two-way switches and a power window lockout switch that are integral to the power window and lock switch unit on the driver side front door trim panel. Additionally, each of the passenger doors has a single gang two- way power window switch mounted in a bezel on their respective door trim panels. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the ON position. However, the LEDs for the passenger power window switches are extinguished whenever the driver selects the Lock position with the power window lockout switch. The power window switch for the driver side front door has an Auto label on it. This switch has a second detent position beyond the normal Down position that provides an automatic one-touch window down feature. This feature is controlled by an electronic circuit and a relay that are integral to the driver side front door power window and lock switch unit. The power window switches control the battery and ground feeds to the power window motors. All of the passenger door power window switches receive their battery and ground feeds through the circuitry of the driver side master switch unit. When the power window lockout switch is in the Lock position, the battery feed for the individual passenger door power window switches is interrupted. The driver side power window and lock switch unit and the single gang passenger door power window switches cannot be repaired and, if faulty or damaged, the entire switch unit or switch must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7269 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, perform the diagnosis for Power Window System. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel. Unplug the wire harness connector from the switch unit, Power Window Switch Continuity - Driver Side Front - Quad Cab Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7270 Power Window Switch Continuity - Front and Rear Passenger Doors - Quad Cab 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, see Power Window Motor. If not OK, replace the faulty switch. NOTE: Because this switch contains active electronic elements for the Auto-down feature, this switch function cannot be checked with a continuity test. If the problem being diagnosed involves this function, reconnect the switch to its wire harness connector, connect the battery negative cable and turn the ignition switch to the ON position. Back probe the wire harness connector cavity for switch pin number 8 and check for the proper switch output while actuating the switch. With the switch in the Up position, there should be continuity to ground at pin 8. With the switch in the Down position, there should be battery voltage at pin 8. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications > Page 7271 Power Window Switch: Service and Repair REMOVAL DRIVER SIDE FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the driver side front door. 3. From the back side of the trim panel, remove the screws that secure the power window and lock switch unit to the switch bezel in the door trim panel opening. 4. Remove the power window and lock switch and the switch bezel from the door trim panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). PASSENGER DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the trim panel from the inside of the front or rear passenger door. 3. With a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power window switch receptacle on the back of the door trim panel switch bezel and pull the switch out of the receptacle. 4. Reverse the removal procedures to install. Be certain that both of the switch snap retainers in the receptacle on the back of the door trim panel switch bezel are fully engaged. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Weatherstrip FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 2 2. Peel seal from door (Fig. 2). INSTALLATION 1. Slide seal into position on door. 2. Install the trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7278 Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 2 2. Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 2). INSTALLATION 1. Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. 2. Push weatherstrip down to seat onto door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7279 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove glass. Fig. 2 2. Pull the glass run weatherstrip and run channels from the window opening (Fig. 2). 3. Pull the glass run weatherstrip from the run channels. INSTALLATION 1. Install the glass run weatherstrip in the run channels. 2. Install the glass run weatherstrip in the window opening. 3. Position the run channels in the door. 4. Install glass. 5. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Inner Belt Weatherstrip > Page 7280 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove trim panel. 2. Remove water dam as necessary to access lower run channels. Fig. 5 3. Remove bolts attaching lower glass run channels to door panel (Fig. 5). 4. Remove glass. 5. Slide lower run channels downward to disengage from upper run channels. 6. Remove lower run channels from door. INSTALLATI0N 1. Position lower run channels in door. 2. Slide lower run channels upward to engage in to upper run channels. 3. Install glass. 4. Install bolts attaching lower glass run channels to door panel. 5. Install water dam. 6. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair BACKLITE REMOVAL 1. Remove liftgate upper trim panel. 2. Remove center high mounted stop lamp. 3. Remove rear window wiper arm, if equipped. 4. Remove side moldings. 5. Cut urethane bonding from around liftgate backlite using a suitable sharp cold knife. A pneumatic cutting device can be used if available. 6. Separate backlite from vehicle. INSTALLATION CAUTION: Open a window before installing backlite. This will avoid pressurizing the passenger compartment. If a door is slammed before urethane is cured, water leaks can result. The window opening fence should be cleaned of old urethane bonding material. 1. Clean inside of backlite with Mopar(R) Glass Cleaner or equivalent and lint-free cloth. 2. Apply PVC (vinyl) primer 25 mm (1 in.) wide around edge of backlite. Wipe with clean/dry lint-free cloth. 3. Apply fence primer around edge of fence. Allow at least eighteen minutes drying time. Fig. 8 4. Install new upper and lower seals on liftgate backlite (Fig. 8). 5. Apply a 12 mm (0.4 in.) bead of urethane around window opening fence. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 7284 Fig. 9 6. Position backlite into window opening (Fig. 9). 7. Install the side moldings. 8. Install the rear wiper arm, if equipped. 9. Install the center high mounted stop lamp. 10. Install the liftgate upper trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair QUARTER WINDOW REMOVAL 1. Remove quarter panel trim. 2. Carefully pull down headliner to access upper nuts attaching quarter window glass to pinchweld and remove nuts. Fig. 7 3. Remove nuts attaching quarter window glass to pinchweld (Fig. 7). 4. Using razor knife, cut butyl sealer between the mounting studs attaching glass to pinchweld. 5. Push glass from opening. INSTALLATION NOTE: The pinchweld should be cleaned of all old butyl sealer. 1. Apply 6 mm (0.25 in.) of butyl tape around perimeter of glass assembly encapsulation track. Ensure the butyl tape is wrapped around the mounting studs. 2. Place glass into opening and insert mounting studs through holes in pinchweld. 3. Install nuts attaching quarter window glass to pinchweld and tighten to 4.5 N.m (40 in. lbs.). 4. Install quarter panel trim. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL 1. Remove waterdam. Refer to Rear Door Panel. Fig. 4 2. Ensure glass is in full up position and supported. Remove bolts attaching the run channels to door inner panel (Fig. 4). 3. Remove speaker, if necessary. 4. Separate run channels from door. INSTALLATION 1. Position run channels in door. 2. Install bolts attaching the run channels to door inner panel (Fig. 4). 3. Install speaker, if necessary. 4. Install waterdam. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7293 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1. Remove trim panel. Fig. 6 2. Pull weatherstrip from inner door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on inner door panel (Fig. 6). 2. Press into place. 3. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7294 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove trim panel. 2. Remove inner belt weatherstrip. 3. Remove outer beltline weatherstrip. Fig. 5 4. Pull weatherstrip from door frame and divider bar channel (Fig. 5). INSTALLATION 1. Position weatherstrip in door frame and divider bar channel. 2. Install outer beltline weatherstrip. 3. Install inner beltline weatherstrip. 4. Install trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7295 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 1. Lower glass. Fig. 6 2. Lift corner of weatherstrip upward and remove weatherstrip from outer door panel (Fig. 6). INSTALLATION 1. Position weatherstrip on outer door panel (Fig. 6). 2. Press into place. 3. Raise glass. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures FRONT DOOR WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 38 Front Door Window Regulator Fig. 39 Power Regulator Bolts 7. Remove screws attaching window regulator to door inner panel. 8. Remove window regulator from door. INSTALLATION Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7301 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator to door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7302 Front Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove door trim panel. 2. Partially remove waterdam. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Disconnect regulator wire harness. Fig. 17 Fig. 18 7. Remove screws attaching window regulator to door inner panel (Fig. 17) and (Fig. 18). 8. Remove window regulator from door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7303 INSTALLATI0N 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Position glass onto window regulator lift channel. 4. Install glass to lift channel fasteners. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching lower front glass run channel to door inner panel. 7. Tighten fasteners holding window regulator door inner panel. 8. Connect regulator wire harness, if equipped. 9. Install waterdam. 10. Install door trim panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures REAR DOOR WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 55 Rear Door Window Regulator - Manual Fig. 56 Rear Door Window Regulator - Power 8. Remove screws attaching window regulator to door inner panel. 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7308 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7309 Rear Door Window Regulator: Removal and Replacement WINDOW REGULATOR REMOVAL 1. Remove upper door trim extension panel. 2. Remove door trim panel. 3. Position glass to access the fasteners. Remove the fasteners. 4. Disengage glass from regulator lift channel. 5. Position glass up into door frame (rest glass on a block of wood on door reinforcement). 6. Lower waterdam. 7. Disconnect regulator wire harness, if equipped. Fig. 13 Fig. 14 8. Remove screws attaching window regulator to door inner panel (Fig. 13) and (Fig. 14). 9. Remove window regulator from door. INSTALLATION 1. Position window regulator in door. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7310 2. Loosely install screws attaching window regulator to door inner panel. 3. Install glass onto regulator lift channel. Secure fasteners. 4. Connect regulator wire harness, if equipped. 5. Cycle the window glass to the full up position. 6. Tighten bolts attaching the regulator to the inner door panel. 7. Install waterdam. 8. Install door trim panel. 9. Install upper door trim extension panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: - DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. - URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. - DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. - BE SURE TO REFER TO THE URETHANE MANUFACTURERS DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. - VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. - SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. - ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7314 Windshield: Service and Repair WINDSHIELD REMOVAL 1. Remove rear view mirror. 2. Remove wiper arms and cowl grille. 3. With doors open, remove the weatherstrip from the side windshield moldings. 4. Remove the screws attaching the side windshield molding to the A-pillars. Fig. 1 5. Cut urethane bonding from around windshield using a suitable sharp cold knife (Fig. 1). 6. Using a long knife, cut urethane bonding from inside the cab at the base of the windshield. INSTALLATION WARNING: ALLOW THE URETHANE AT LEAST 24 HOURS TO CURE BEFORE RETURNING THE VEHICLE TO USE. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. Fig. 2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7315 NOTE: The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening (Fig. 2) should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening. Fig. 3 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening (Fig. 3). Fig. 4 2. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4). 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint-free cloth. 5. Apply pinchweld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 7316 Fig. 5 6. Apply a 13 mm (l/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield. At the bottom, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the three sides where the molding is on the glass, follow the edge of molding. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator (Fig. 5). 7. With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. 8. Slowly lower windshield glass to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass onto fence along the A-Pillars. Push windshield inward to the fence at the bottom corners. 9. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 10. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 11. Install new screws attaching the side windshield moldings to the A-pillars. 12. Install the weatherstrip onto side windshield moldings. 13. Install cowl grille. 14. Install the wiper arms. 15. Install the rear view mirror bracket. 16. Install rear view mirror. 17. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Locations Check Valve: Locations Check valve is located in the washer supply hose near the top of the right liftgate opening pillar. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Locations > Page 7321 Check Valve: Service and Repair REMOVAL A check valve is located in the washer supply hose near the top of the right liftgate opening pillar. 1. Remove the right upper D-pillar trim. 2. Disconnect the washer supply hoses from the barbed nipples on each end of the rear washer system check valve. 3. Remove the check valve from the vehicle. Rear Washer System Check Valve 4. When reinstalling the check valve, be certain the valve is properly oriented within the system flow. 5. Reverse the remaining removal procedures to complete the installation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7326 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7327 Wiper Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7328 Wiper Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7329 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7330 Wiper Relay: Description and Operation The intermittent wipe 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7331 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. RELAY TEST Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Removal and Installation 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 Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7332 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7337 Washer Fluid Level Switch: Description and Operation The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7338 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Washer Pump And Washer Fluid Level Sensor Remove/Install 2. Disconnect the headlamp and dash wire harness connector from the connector receptacle on the washer fluid level sensor. 3. Disconnect the washer supply hose from the outlet nipple of the front washer pump. Drain the washer fluid from the reservoir into a clean container for reuse. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal in the washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7342 Windshield Washer Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7343 Windshield Washer Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7344 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7345 Windshield Washer Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7346 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7347 Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7351 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7352 Wiper Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7353 Wiper Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7354 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7355 Wiper Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7356 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7357 Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions Washer Fluid Level Indicator: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions > Page 7361 Washer Fluid Level Indicator: Application and ID CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Bulb Application Low Washer Fluid ................................................................................................................................ ................................................................... PC194 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Service Precautions > Page 7362 Washer Fluid Level Indicator: Testing and Inspection On each of the lamps found depends upon a hard wired circuit input to the instrument cluster for proper operation. The following procedures will help to diagnose conditions that may cause an inoperative hard wired lamp circuit condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Low Washer Fluid Warning Lamp The diagnosis found here addresses an inoperative low washer fluid warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or washer fluid level sensor and not with a damaged or empty washer fluid reservoir. Inspect the reservoir for proper fluid level and signs of damage or distortion that could affect sensor performance before you proceed with lamp diagnosis. 1. Check the fused ignition switch output (run/ start) fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 3. Turn the ignition switch to the OFF position. Disconnect the wire harness connector from the washer fluid level sensor. Install a jumper wire between the two cavities of the washer fluid level sensor wire harness connector. Turn the ignition switch to the ON position. About thirty seconds after the ignition switch is turned to the ON position, the low washer fluid warning lamp should light. Turn the ignition switch to the OFF position. Remove the jumper wire from the washer fluid level sensor connector. Turn the ignition switch to the ON position and, following the cluster bulb check sequence, the lamp should go OFF. If OK, replace the faulty washer fluid level sensor. If not OK, go to Step 4. NOTE: If the ignition switch is in the ON position when the washer fluid level sensor circuit is grounded, the instrument cluster programming will double the low washer fluid warning lamp illumination delay time from thirty seconds to about sixty seconds. This feature is intended to compensate for the reflects of washer fluid sloshing within the washer fluid reservoir while the vehicle is being driven. 4. Turn the ignition switch to the OFF position. Check for continuity between the ground circuit cavity of the washer fluid level sensor wire harness connector and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required. 5. Disconnect and isolate the battery negative cable. Remove the instrument cluster. With the washer fluid level sensor wire harness connector still disconnected, check for continuity between the low washer fluid level sense circuit cavity of the instrument cluster wire harness connector B and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted low washer fluid level sense circuit as required. 6. Check for continuity between the low washer fluid level sense circuit cavities of the instrument cluster wire harness connector B and the washer fluid level sensor wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open low washer fluid level sense circuit as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7366 Washer Fluid Level Switch: Description and Operation The standard washer fluid level sensor is mounted on the right outboard end of the upper radiator shroud near the front of the windshield washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7367 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Washer Pump And Washer Fluid Level Sensor Remove/Install 2. Disconnect the headlamp and dash wire harness connector from the connector receptacle on the washer fluid level sensor. 3. Disconnect the washer supply hose from the outlet nipple of the front washer pump. Drain the washer fluid from the reservoir into a clean container for reuse. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector receptacle is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal in the washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations The washer pumps and motors are mounted on the right end of the upper radiator shroud near the bottom of the washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7371 Windshield Washer Pump: Description and Operation The washer pumps and motors are mounted on the right end of the upper radiator shroud near the bottom of the washer reservoir. A barbed nipple on the pump housing passes through a rubber grommet seal installed in a hole near the bottom of the reservoir. The washer pump is retained by an interference fit between the barbed pump nipple and the grommet seal, which is a light press fit. A permanently lubricated and sealed motor is coupled to a rotor-type pump. Washer fluid is gravity-fed from the reservoir to the pump. When the motor is energized, the pump pressurizes the washer fluid and forces it through the plumbing to the nozzles. The washer pump and motor units cannot be repaired. If faulty, the entire washer pump and motor unit must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7372 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Washer Pump And Washer Fluid Level Sensor Remove/Install 2. Disconnect the headlamp and dash wire harness connector from the connector receptacle on the front or rear washer pump. 3. Disconnect the washer supply hose from the outlet nipple of the front or rear washer pump. Drain the washer fluid from the reservoir into a clean container for reuse. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed inlet nipple of the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal in the washer reservoir. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations Windshield Washer Reservoir: Locations Washer Reservoir Remove/Install The washer fluid reservoir is integral to and located on the right end of the upper radiator shroud in the engine compartment. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Locations > Page 7376 Windshield Washer Reservoir: Description and Operation The washer fluid reservoir is integral to and located on the right end of the upper radiator shroud in the engine compartment. Both the washer pump and motor unit and the washer fluid level sensor have barbed nipples, which are installed through a rubber grommet seal inserted in holes on the right end of the upper radiator shroud and reservoir unit. The washer pump and washer fluid level sensor are retained by an interference fit between the barbed nipple and the grommet seal, which is a light press fit. The washer reservoir has a snap-fit filler cap with a rubber gasket. The cap hinges on and is secured to a molded-in hook formation on the top of the fan shroud, just inboard of the reservoir filler neck. The washer reservoir grommet seals and filler cap are each available for service. The washer reservoir is serviced only as a unit with the upper radiator shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation FRONT Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the washer pump. The hose is routed from the washer reservoir to the dash panel along the top of the right front wheelhouse inner panel. At the dash panel, the hose passes through a grommet inserted in a hole in the cowl plenum panel to an in-line fitting located in the cowl plenum area, beneath the cowl plenum cover! grille panel. A hose from the mAine fitting in the cowl plenum is routed through clips molded into the underside of the cowl plenum cover/grille panel to a wye fitting near the passenger side washer nozzle. Hoses from the wye fitting are routed to the two washer nozzles, which are snap-fit into openings in the cowl plenum cover/grille panel. The wye fitting includes an integral check valve to prevent the washer fluid from draining from the nozzles back to the reservoir or from leaking out of the nozzles after washer operation is complete. The two fluidic washer nozzles are not adjustable. The nozzles and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. REAR Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the rear window washer pump. The hose is routed from the washer reservoir to the dash panel along the top of the right front wheelhouse inner panel. At the dash panel, the hose passes through a grommet in the dash panel into the passenger compartment. Inside the passenger compartment the hose is routed down the right cowl side inner panel to the sill, then along the sill to the right quarter inner panel. The hose is routed along the quarter inner panel and up the right lift-gate opening pillar to the liftgate opening header. Located near the top of the supply hose routing, beneath the right liftgate opening pillar trim, the hose connects to a check valve. The check valve prevents washer fluid drain-back or siphoning from occurring. From the check valve, another single hose is routed to the liftgate opening header panel. There the hose passes through a grommet out of the liftgate opening header and through another grommet into the top of the liftgate inner panel. Within the lift-gate, the hose is connected to a nipple that protrudes from the fluidic washer nozzle, which is snap-fit into a keyed hole in the top of the liftgate outer panel. The rear window washer nozzle cannot be adjusted. The nozzle, check valve, and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7380 Windshield Washer Spray Nozzle: Service and Repair REMOVAL FRONT 1. Remove the cowl plenum cover/grille panel from the cowl top. 2. From the underside of the cowl plenum coven grille panel, disconnect the washer hose from the nozzle fitting. 3. From the underside of the cowl plenum coven grille panel, compress the retaining tabs of the washer nozzle and push the nozzle out through the top of the panel. 4. Reverse the removal procedures to install. REAR 1. Using a trim stick or another suitable wide flat-bladed tool, pry gently at each side of the rear washer nozzle to release the snap clips that secure it to the liftgate outer panel. 2. Pull the nozzle out from the liftgate outer panel far enough to access and disconnect the washer supply hose from the nozzle nipple. 3. Reverse the removal procedures to install. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Switch Mounting Screws 2.2 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7384 Windshield Washer Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7385 Windshield Washer Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7386 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7387 Windshield Washer Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7388 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 7389 Rear Window Switch Pod Remove/Install 3. Remove the two screws that secure the rear window switch pod to the instrument panel lower bezel. 4. Remove the rear window switch pod from the instrument panel lower bezel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 Nm (20 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation All Durango models have two 50-centimeter (19.69-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). The driver side and passenger side wiper blades are not interchangeable. The driver side blade features an additional bridge, which provides an additional set of claws to retain the wiper squeegees than the six sets of claws used on the passenger side blade. These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. The standard rear wiper uses a single 40.0-centimeter (15.75-inch) wiper blade with a non-replaceable rubber element (squeegee). Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness, Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield or rear glass should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by a nut to each of the two wiper pivots that protrude through the cowl plenum cover/grille panel at the base of the windshield. The rear wiper arm is secured by a nut directly to the rear wiper motor output shaft on the liftgate below the rear window glass. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7393 Wiper Arm: Service and Repair REMOVAL AND INSTALLATION CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This distortion could allow the arm to come oft of the pivot shaft, regardless of how carefully it is installed. FRONT 1. Open the hood of the vehicle. Wiper Arm Remove/Install 2. Carefully pry the plastic nut cap off of the nut on the pivot end of the wiper arm. 3. Remove the nut that secures the wiper arm to the wiper pivot. Wiper Arm Puller 4. Use a battery terminal puller to remove the wiper arm from the wiper pivot. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7394 Wiper Arm Installation 5. Install the arm and blade with the wiper motor in the Park position. See the Wiper Arm Installation illustration. 6. Mount the arms on the pivot shafts so that the front and rear edges of the wiper blade are aligned with the wiper alignment lines concealed in the upper margin of the lower windshield blackout area, ± 15 mm (± 0.59 in.). 7. Install the wiper arm pivot nuts and tighten to 24 Nm (212 in. lbs.). 8. Operate the wipers with the windshield glass wet, then turn the wiper switch to the OFF position. Check for the correct wiper arm positioning and readjust if required. 9. Install the plastic nut caps onto the wiper arm pivot nuts. REAR Rear-Wiper Arm Remove/Install 1. Carefully pry the plastic nut cap off of the nut on the rear wiper motor output shaft end of the wiper arm. 2. Remove the nut that secures the wiper arm to the rear wiper motor output shaft. 3. Use a battery terminal puller to remove the wiper arm from the wiper pivot. 4. Install the arm and blade with the rear wiper motor in the Park position. 5. Mount the wiper arm on the rear wiper motor output shaft so that the center of the wiper blade is located between the upper margin of the lower rear window blackout area and the lower edge of the trademark on the lower right corner of the rear window glass. 6. Install the nut that secures the wiper arm to the rear wiper motor output shaft. Tighten the mounting nut to 18 Nm (160 in. lbs.). 7. Operate the rear wiper with the rear window glass wet, then turn the rear wiper switch to the OFF position. Check for the correct wiper arm positioning and readjust if required. 8. Install the plastic nut cap onto the nut on the rear wiper motor output shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7408 Wiper Blade: Description and Operation All Durango models have two 50-centimeter (19.69-inch) windshield wiper blades with non-replaceable rubber elements (squeegees). The driver side and passenger side wiper blades are not interchangeable. The driver side blade features an additional bridge, which provides an additional set of claws to retain the wiper squeegees than the six sets of claws used on the passenger side blade. These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly when installed on the wiper arms for the anti-lift feature to be effective. The standard rear wiper uses a single 40.0-centimeter (15.75-inch) wiper blade with a non-replaceable rubber element (squeegee). Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn, or contaminated, the entire wiper blade assembly must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness, Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms, and windshield or rear glass should be cleaned with a sponge or cloth and windshield washer fluid, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, the wiper blades should be replaced. The blades are mounted to spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The windshield wiper arms are secured by a nut to each of the two wiper pivots that protrude through the cowl plenum cover/grille panel at the base of the windshield. The rear wiper arm is secured by a nut directly to the rear wiper motor output shaft on the liftgate below the rear window glass. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7409 Wiper Blade: Service and Repair REMOVAL AND INSTALLATION FRONT NOTE: The driver side and passenger side wiper blades are not interchangeable. The driver side wiper blade has an extra bridge and eight pairs of claws securing the wiper element. The passenger side wiper blade has six pairs of claws securing the wiper element. The notched retainer end of both wiper elements should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Turn the windshield wiper switch to the ON position. By turning the ignition switch to the On and OFF positions, cycle the wiper blades to a convenient working location on the windshield. 2. Lift the wiper arm to raise the wiper blade and element off of the windshield glass. Wiper Blade Remove/Install - Typical 3. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide the blade away from the tip towards the pivot end of the arm. 4. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the wiper pivot. REAR NOTE: The notched retainer end of the wiper element should always be oriented towards the end of the wiper blade that is nearest to the rear wiper motor output shaft. Rear Wiper Blade Remove/Install 1. To remove the wiper blade from the wiper arm, lift up the retainer release tab on the top of the wiper arm to unlatch it from the wiper arm. 2. Raise the retainer release tab until it is perpendicular to the rear wiper blade. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7410 3. Slide the rear wiper blade towards the rear wiper motor output shaft end of the rear wiper arm to disengage the blade retainer pivot from the U-shaped formation on the tip of the wiper arm. 4. Lift up slightly on the rear wiper arm and slide the rear wiper blade off of the tip of the wiper arm through the retainer window. 5. To install the rear wiper blade onto the rear wiper arm, lift the rear wiper blade retainer release tab until it is perpendicular to the wiper blade. 6. Lift up slightly on the rear wiper arm and slide the rear wiper blade retainer window over the U-shaped formation on the tip of the wiper arm. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the rear wiper motor output shaft. 7. Release the rear wiper arm and slide the rear wiper blade towards the tip of the wiper arm until the pivot of the blade retainer is engaged in the U-shaped formation on the tip of the wiper arm. 8. Press down on the rear wiper blade retainer release tab until it snaps into its locked position over the top of the rear wiper arm. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Rear Wiper Motor Mounting Bracket Screws 8.1 Nm Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7414 Wiper Motor Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7415 Wiper Motor: Description and Operation FRONT The two-speed permanent magnet wiper motor has an integral transmission and park switch. The motor also contains an internal automatic resetting circuit breaker to protect the motor from overloads. The motor is secured near the center of the tubular wiper linkage and pivot module bracket with three screws. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. Wiper speed is controlled by current flow to the proper set of brushes. The wiper motor completes its wipe cycle when the windshield wiper switch on the end of the multi-function switch stalk is turned to the OFF position, and parks the blades in the lowest portion of the wipe pattern. The windshield wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this unit is faulty or damaged, the entire wiper module must be replaced. REAR The rear wiper motor is secured to a bracket that is fastened to the liftgate inner panel with two screws through two rubber grommet-type insulators, below the rear window glass and behind the liftgate trim panel. The motor output shaft passes through the liftgate outer panel where a rubber grommet and a nut seal and secure the unit to the liftgate outer panel. A plastic cover snaps onto the motor output shaft to conceal the mounting nut. The rear wiper arm is secured directly to the motor output shaft with another nut, which is also concealed by a plastic cover that snaps onto the end of the wiper arm. The rear wiper motor unit provides a single speed intermittent-cycle operating mode, which is provided by an electronic timer circuit that is integral to the motor unit. The rear wiper motor cannot be repaired. If faulty or damaged, the entire rear wiper motor assembly must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7416 Wiper Motor: Service and Repair REMOVAL FRONT 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms from the wiper pivots. Cowl Plenum Cover/Grille Panel Weatherstrip 3. Remove the weatherstrip along the front edge of the cowl plenum cover/grille panel and the cowl plenum panel. Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the one plastic rivet that secures the front corner on each side of the cowl plenum coven grille panel to the cowl plenum panel. 6. Remove the one plastic push-in retainer that secures the rear corner on each side of the cowl plenum cover/grille panel to the windshield reveal moulding. 7. Unsnap the slotted center hole on each side of the cowl plenum cover/grille panel from the adhesive backed snap fastener. This fastener is secured to the top of each cowl side panel with an adhesive backing, and should not be removed during cowl plenum cover/grille panel removal. 8. Lift the cowl plenum cover/grille panel from the cowl top far enough to access the windshield washer nozzle and vacuum plumbing near the right end of the cowl plenum. 9. Disconnect the windshield washer supply hose at the in-line connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7417 Vacuum Reservoir 10. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured to the underside of the right end of the cowl plenum cover/grille panel. 11. Remove the cowl plenum cover/grille panel from the vehicle and set it aside. Wiper Module Remove/Install 12. Remove the four screws that secure the wiper module to the cowl plenum panel. 13. Move the wiper module as required to access the wiper motor wire harness connector. 14. Unplug the wiper motor wire harness connector from the wiper motor. 15. Remove the wiper module from the cowl plenum. 16. Reverse the removal procedures to install. Be certain that the washer nozzle hoses are correctly routed and installed in the retainers on the underside of the cowl plenum cover/grille panel. Tighten the mounting screws to 8 Nm (72 in. lbs.). REAR 1. Disconnect and isolate the battery negative cable. 2. From the outside of the liftgate, remove the rear wiper arm from the rear wiper motor output shaft. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 7418 Rear Wiper Motor Remove/Install 3. Use a door trim panel removal tool to gently pry at the base of the nut cover where it meets the wiper motor output shaft bezel and grommet on the outer liftgate panel until it unsnaps from the rear wiper motor output shaft. Be certain to use proper caution to protect the outer liftgate panel and its paint finish from damage during this procedure. 4. Remove the nut that secures the rear wiper motor output shaft to the outer liftgate panel. 5. Pull the bezel and grommet off of the rear wiper motor output shaft. 6. Remove the liftgate trim panel from the lift- gate. 7. Unplug the rear wiper motor wire harness connector. 8. While supporting the wiper motor with a free hand, remove the two screws that secure the rear wiper motor mounting bracket to the liftgate inner panel. 9. Remove the rear wiper motor and mounting bracket from the liftgate as a unit. 10. When reinstalling the rear wiper motor to the liftgate, first position the motor and bracket to the liftgate inner panel and secure it by loosely installing the mounting screws. 11. From the outside of the liftgate, center the rear wiper motor output shaft in the liftgate outer panel mounting hole and secure it with the shaft retaining nut. Tighten the nut to 4.8 Nm (43 in. lbs.). 12. Reverse the remaining removal procedures to complete the installation. Tighten the rear wiper motor mounting bracket screws to 8.1 Nm (72 in. lbs.). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation The wiper linkage and pivot module is secured with four screws through four rubber grommet-type insulators to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws near the center of the tubular linkage and pivot module bracket, and the wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket- type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve- type bushing end is then fit over the motor crank arm ball stud, and the second socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 7422 Wiper Motor Linkage: Service and Repair REMOVAL AND INSTALLATION The wiper linkage and pivots can only be removed from or installed in the vehicle as a unit with the wiper motor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation The wiper linkage and pivot module is secured with four screws through four rubber grommet-type insulators to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws near the center of the tubular linkage and pivot module bracket, and the wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket- type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve- type bushing end is then fit over the motor crank arm ball stud, and the second socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 7426 Wiper Pivot: Service and Repair REMOVAL AND INSTALLATION The wiper linkage and pivots can only be removed from or installed in the vehicle as a unit with the wiper motor. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Power Distribution Center Wiper Relay is located in the Power Distribution Center (PDC). Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7430 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7431 Wiper Relay: Diagrams 8w-12-2 Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7432 Wiper Relay Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7433 Wiper Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7434 Wiper Relay: Description and Operation The intermittent wipe 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 (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and if faulty or damaged, it must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7435 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. RELAY TEST Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Removal and Installation 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 Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7436 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe 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. 8. Test the relay operation. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi - Function Switch Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7440 Wiper Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7441 Wiper Switch: Description and Operation FRONT Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. REAR The single two-function rear wiper and washer switch is integral to the rear window switch pod, which includes the rear window defogger switch. The rear window switch pod is installed in the instrument panel lower bezel, which is located near the center of the lower instrument panel, below the heater and air conditioner controls. The rear wiper and washer switch controls the rear wiper and washer functions. The rear window switch pod also contains the rear window defogger logic and timer circuitry, an amber defogger indicator lamp, the rear window defogger relay, and two switch illumination lamps. The indicator and illumination lamps in the switch pod use incandescent bulbs, which can be serviced. The sliding-type switch features a detent in the ON position for the rear wiper. Pushing in on the rear wiper switch button activates the momentary rear washer switch. The rear wiper and washer switch also has an integral illumination lamp with a serviceable bulb. Both the rear wiper and rear washer motors will operate continuously for as long as the switch is held in the momentary Wash position. The rear wiper and washer switch cannot be repaired and, if faulty or damaged, the entire rear window switch pod must be replaced. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7442 Wiper Switch: Testing and Inspection FRONT See Wiper System and/or Washer System in the Diagnosis and Testing. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. REAR Perform the diagnosis for the rear wiper system and/or washer system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the lower bezel from the instrument panel and unplug the rear window switch pod wire harness connector. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7443 Rear Wiper Switch And Washer Switch Continuity 2. Using an ohmmeter, check the rear wiper and washer switch continuity at the rear window switch pod terminals as shown in the Rear Wiper Switch and Washer Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty rear window switch pod. If the switch is OK, repair the rear wiper system and/or washer system wire harness circuits as required. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7444 Wiper Switch: Service and Repair REMOVAL FRONT WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Dodge Durango 2wd Workshop Manual (V8-5.9L VIN Z LDC (2000)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7445 Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR2OB2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 Nm (17 in. lbs.) - Multi-function switch mounting screws - 2 Nm (17 in. lbs.). REAR WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIRBAGS AND SEAT BELTS/AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower bezel from the instrument panel.