Dodge - Ram 1500 2wd - Workshop Manual - 2003 - 2003 (2)

Factory Workshop Manual Make Dodge Model Ram 1500 2wd Engine and year Truck V6-3.7L VIN K (2003) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Description and Operation Accessory Delay Relay: Description and Operation ACCESSORY RELAY The accessory relay works in conjunction with the FCM's power accessory delay features to control the operation of the radio, power windows, washer pump motors, wiper motor and power outlets. The accessory relay is turned ON by the FCM See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Modulethrough the relay's low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain ON or will time out and deactivate. The accessory relay remains ON in the RUN and ACCY ignition switch positions. In the UNLK and OFF positions, the relay will remain energized for 45 seconds and then deactivate. During this time-out period, if a driver or passenger door is opened, the relay will be deenergized immediately. While the ignition switch is in the START position, the relay will also drop out and then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren Alarm Module: Customer Interest Alarm System - Erroneous Horn Chirp/Alarm Siren NUMBER: 08-016-02 GROUP: Electrical DATE: September 2, 2002 SUBJECT: Horn Chirp and Erroneous Alarm OVERVIEW: This bulletin involves reprogramming the Forward Control Module (FCM) MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Two conditions have been identified which could be caused by electronic communication errors between the Forward Controller Module (FCM) and other electronic modules on the vehicle: The first condition can occur after a vehicle has been turned off and allowed to sit for more than a three minutes. A very brief horn chirp can sometimes be heard when a door is opened. When the engine is turned off the electronic modules continue to function, or stay awake for two to three minutes after shut down. After two to three minutes of inactivity the modules deactivate or go into a sleep mode. When a door is opened, the modules are activated or wake up. The brief horn chirp will occur at the time the modules wake up or when the door is opened. This can occur due to a communication error in the FCM. The second condition involves vehicles NOT equipped with Vehicle Theft Security System (VTSS) exhibiting an alarm with the horn sounding and lights flashing. This can also be caused by communication errors involving the FCM. Both of these condition have been corrected with software revisions in the FCM. Reprogramming the FCM with the latest software revision (version 5.4) will correct the conditions. DIAGNOSIS: If the vehicles exhibit either of the conditions described above, perform the Repair Procedure and reprogram the Front Controller Module (FCM). EQUIPMENT REQUIRED REPAIR PROCEDURE: 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the Front Controller Module (FCM) using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). The FCM software must be version 5.4 or later. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren > Page 16 FAILURE CODE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren Alarm Module: All Technical Service Bulletins Alarm System - Erroneous Horn Chirp/Alarm Siren NUMBER: 08-016-02 GROUP: Electrical DATE: September 2, 2002 SUBJECT: Horn Chirp and Erroneous Alarm OVERVIEW: This bulletin involves reprogramming the Forward Control Module (FCM) MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Two conditions have been identified which could be caused by electronic communication errors between the Forward Controller Module (FCM) and other electronic modules on the vehicle: The first condition can occur after a vehicle has been turned off and allowed to sit for more than a three minutes. A very brief horn chirp can sometimes be heard when a door is opened. When the engine is turned off the electronic modules continue to function, or stay awake for two to three minutes after shut down. After two to three minutes of inactivity the modules deactivate or go into a sleep mode. When a door is opened, the modules are activated or wake up. The brief horn chirp will occur at the time the modules wake up or when the door is opened. This can occur due to a communication error in the FCM. The second condition involves vehicles NOT equipped with Vehicle Theft Security System (VTSS) exhibiting an alarm with the horn sounding and lights flashing. This can also be caused by communication errors involving the FCM. Both of these condition have been corrected with software revisions in the FCM. Reprogramming the FCM with the latest software revision (version 5.4) will correct the conditions. DIAGNOSIS: If the vehicles exhibit either of the conditions described above, perform the Repair Procedure and reprogram the Front Controller Module (FCM). EQUIPMENT REQUIRED REPAIR PROCEDURE: 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the Front Controller Module (FCM) using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). The FCM software must be version 5.4 or later. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren > Page 22 FAILURE CODE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 23 Fig.32 Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 24 Sentry Key Immobilizer Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 25 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIS programming enables the SKIM to program and retain in memory the codes of at least two, but no more than eight electronically coded Sentry Key transponders. The SKIS programming also enables the SKIM to communicate over the Programmable Communication Interface (PCI) bus network with the Powertrain Control Module (PCM), and/or the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the ignition lock cylinder housing. This antenna ring must be located within eight millimeters (0.31 inches) of the Sentry Key in order to ensure proper RF communication between the SKIM and the Sentry Key transponder. For added system security each SKIM is programmed with a unique "Secret Key" code and a security code. The SKIM keeps the "Secret Key" code in memory The SKIM also sends the "Secret Key" code to each of the programmed Sentry Key transponders. The security code is used by the assembly plant to access the SKIS for initialization, or by the dealer technician to access the system for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a PCI bus message from the PCM during initialization. The SKIM and the PCM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized SKIS disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM. However, the use of this strategy also means that replacement of either the SKIM or the PCM units will require a system initialization procedure to restore system operation. When the ignition switch is turned to the ON or START positions, the SKIM transmits an RF signal to excite the Sentry Key transponder. The SKIM then listens for a return RF signal from the transponder of the Sentry Key that is inserted in the ignition lock cylinder. If the SKIM receives an RF signal with valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. The SKIM also sends messages to the Instrument Cluster which controls the VTSS indicator LED. The SKIM sends messages to the Instrument Cluster to turn the LED ON for about three seconds when the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the LED OFF for a duration of about one second. Then the SKIM sends messages to turn the LED ON or OFF based upon the results of the SKIS self-tests. If the VTSS indicator LED comes ON and stays ON after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the ON position, it sends messages to flash the VTSS indicator LED. The SKIM can also send messages to flash the LED as an indication to the customer that the SKIS has been placed in it's "Customer Learn" programming mode. See Sentry Key Immobilizer System Transponder Programming in this section for more information on the "Customer Learn" programming mode. For diagnosis or initialization of the SKIM and the PCM, a DRB III scan tool and the proper Powertrain Diagnostic Procedures manual are required. The SKIM cannot be repaired and, if faulty or damaged, the unit must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 26 Alarm Module: Testing and Inspection STANDARD PROCEDURE - PCM/SKIM PROGRAMMING NOTE: There are two procedures for transfering the secret key to the SKIM: When ONLY the SKIM module is replaced, the secret key is transferred from the PCM to the SKIM. The ORGINAL KEYS may then be programmed to the SKIM. - When ONLY the PCM is replaced, then the secret key is transfered from the SKIM to the PCM. The ORGINAL KEYS may be used. - When BOTH the SKIM and the PCM are replaced the secret key is transferred from the SKIM to the PCM, and NEW KEYS must be programmed. NOTE: Before replacing the Powertrain Control Module (PCM) for a failed driver, control circuit, or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one Diagnostic Trouble Code (DTC) has set. When a PCM (SBEC) and the Sentry Key Immobilizer Module (SKIM) are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC). 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM (SBEC) The Sentry Key Immobilizer System (SKIS) Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRBIII scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRBIII scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRBIII scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III® scan tool. If NO is selected, the DRBIII scan tool will read, Enter odometer Reading. Enter the odometer reading from the instrument cluster and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRBIII scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select SKIM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into the SKIM, the SKIM must be replaced. 6. Select YES to update the VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key information to the SKIM). 8. Program ignition keys to the SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRBIII scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, it (the key) cannot be transferred to another vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 27 5. If ignition key programming is unsuccessful, the DRBIII scan tool will display one of the following messages: a. Programming Not Attempted - The DRBIII scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. b. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: - Faulty ignition key transponder. - Ignition key is programmed to another vehicle. c. 8 Keys Already Learned, Programming Not Done - SKIM transponder ID memory is full. 6. Obtain ignition keys to be programmed from customer (8 keys maximum). 7. Using the DRBIII scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 8. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > PCM (SBEC) and the Sentry Key Immobilizer Module Alarm Module: Service and Repair PCM (SBEC) and the Sentry Key Immobilizer Module NOTE: 1. There are two procedures for transfering the secret key to the SKIM: - When ONLY the SKIM module is replaced, the secret key is transfered from the PCM to the SKIM. The ORGINAL KEYS may then be programmed to the SKIM. - When ONLY the PCM is replaced, then the secret key is transfered from the SKIM to the PCM. The ORGINAL KEYS may be used. - When BOTH the SKIM and the PCM are replaced the secret key is transferred from the SKIM to the PCM, and NEW KEYS must be programmed. 2. Before replacing the Powertrain Control Module (PCM) for a failed driver, control circuit, or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one Diagnostic Trouble Code (DTC) has set. When a PCM (SBEC) and the Sentry Key Immobilizer Module (SKIM) are replaced at the same time perform the following steps in order: 1. Program the new PCM (SBEC). 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > PCM (SBEC) and the Sentry Key Immobilizer Module > Page 30 Alarm Module: Service and Repair Sentry Key Immobilizer Module Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column upper and lower shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the steering column wire harness connector from the Sentry Key Immobilizer Module (SKIM) Fig. 8. Sentry Key Immobilizer Module 4. Remove the screw securing the SKIM module to the steering column. 5. Release the SKIM antenna ring retaining clips from around the ignition switch lock cylinder housing and remove the SKIM. INSTALLATION NOTE: If the SKIM is replaced with a new unit, a DRBIII scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. 1. Slide the SKIM antenna ring around the ignition switch lock cylinder housing and clip in place. 2. Install the retaining screw. 3. Connect the steering column wire harness connector to the Sentry Key Immobilizer Module (SKIM). 4. Install the steering column upper and lower shrouds. Refer to Steering, Column, Shroud, Installation. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > PCM (SBEC) and the Sentry Key Immobilizer Module > Page 31 Alarm Module: Service and Repair Programming the Sentry Key Immobilizer Module PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRBIII scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select SKIM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into the SKIM, the SKIM must be replaced. 6. Select YES to update the VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key information to the SKIM). 8. Program ignition keys to the SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > PCM (SBEC) and the Sentry Key Immobilizer Module > Page 32 Alarm Module: Service and Repair Programming Ignition Keys to the SKIM PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRB III scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, it (the key) cannot be transferred to another vehicle. 5. If ignition key programming is unsuccessful, the DRB III scan tool will display one of the following messages: a. Programming Not Attempted - The DRB III scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory b. Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following: - Faulty ignition key transponder. - Ignition key is programmed to another vehicle. c. 8 Keys Already Learned, Programming Not Done - SKIM transponder ID memory is full. 6. Obtain ignition keys to be programmed from customer (8 keys maximum). 7. Using the DRB III scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 8. Program all ignition keys. Learned Key In Ignition - Ignition key transponder ID is currently programmed in SKIM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 36 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned OFF, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to pulse for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Refer to the owner's manual for more information on the features, use and operation of the RKE system. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a DRB III scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, (Refer to POWER LOCKS/KEYLESS ENTRY TRANSMITTER - STANDARD PROCEDURE). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 37 Keyless Entry Module: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Refer to the proper Body Diagnostic Procedures Manual for testing the Remote Keyless Entry system using a DRB III scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 38 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster (Refer to INSTRUMENT CLUSTER - REMOVAL). Fig. 5 Remote Keyless Entry Module 3. Remove remote keyless entry module from instrument cluster. INSTALLATION 1. Install remote keyless entry module to instrument cluster. 2. Install instrument cluster (Refer to INSTRUMENT CLUSTER - INSTALLATION) 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions Pedal Positioning Module: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Pedal Positioning Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Diagrams > Page 66 Pedal Positioning Module: Description and Operation ADJUSTABLE PEDALS SYSTEM For this vehicle, the adjustable pedal system has no dedicated module controller. The brake, clutch, and accelerator pedal position is controlled by a manual switch located on the instrument panel. ADJUSTABLE PEDALS RELAY The adjustable pedals relay is located in the Integrated Power Module (IPM). The relay, when not activated, supplies fused battery power to the Adjustable Pedals Switch. If the Front Control Module (FCM) receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch. The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations Fig.42 Standard Cab Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 71 Door Module: Diagrams Driver Door Module C1 Driver Door Module C2 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 72 Door Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) is used on all models equipped with power locks, power windows, and power mirrors. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way, momentary, resistor multiplexed switch to control the power lock system. Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light- Emitting Diodes (LED s) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility in dark ambient lighting conditions. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 73 Door Module: Testing and Inspection DRIVER DOOR MODULE The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Fig.2 Driver Door Module Connector C1 Receptacle Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 74 Fig. 3 Driver Door Module Connector C2 Receptacle (Part 1 Of 2) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 75 Fig. 3 Driver Door Module Connector C2 Receptacle (Part 2 Of 2) 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 76 Door Module: Service and Repair DRIVER DOOR MODULE REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 4 Driver Door Module 2. Using a trim stick, gently pry the driver door module from the door panel. 3. Disconnect the electrical harness connectors from the driver door module. INSTALLATION 1. Connect electrical harness connectors to the driver door module. 2. Position driver door module to door trim panel and press into place. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Heated Mirror Relay: Locations Integrated Power Module Heated Mirror Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 80 Heated Mirror Relay: Description and Operation ELECTRICALLY HEATED SYSTEMS HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTC's. A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Information Bus Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 81 Heated Mirror Relay: Testing and Inspection DIAGNOSIS AND TESTING - HEATED MIRROR SYSTEM If only one of the outside mirror heating grids is inoperative, perform continuity checks on the circuits and heater grid for that mirror only. If both outside mirror heating grids are inoperative, proceed with the heated mirror system diagnosis as follows. (Refer to Appropriate Wiring Information)See: Diagrams WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The operation of the heated mirror system can be confirmed in one of the following manners: 1. Turn the ignition switch to the On position. While monitoring the instillment panel voltmeter, momentarily depress and release the heated mirror switch. When the heated mirror system is turned on, a distinct voltmeter needle deflection should be noted 2. Turn the ignition switch to the On position. Momentarily depress and release the heated mirror switch to turn the heated mirror system On. The heated mirror operation can be checked by feeling the outside rear view mirror glass. A distinct difference in temperature between the unheated and heated mirror glass can be detected within three to four minutes of system operation. The above checks will confirm system operation. Illumination of the heated mirror system indicator lamp means that there is electrical current available at the heated mirror relay, but does not confirm that the electrical current is reaching the outside mirror heating grids. If the heated mirror system does not operate, the problem should be isolated in the following manner: 1. Confirm that the ignition switch is in the On position. 2. Check the fuses in the Power Distribution Center (PDC) and in the Junction Block (JB). The fuses must be tight in their receptacles and all electrical connections must be secure. See: Power and Ground Distribution When the above steps have been completed and both outside mirror heating grids are still inoperative, one or more of the following is faulty: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 85 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned OFF, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to pulse for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Refer to the owner's manual for more information on the features, use and operation of the RKE system. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a DRB III scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, (Refer to POWER LOCKS/KEYLESS ENTRY TRANSMITTER - STANDARD PROCEDURE). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 86 Keyless Entry Module: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Refer to the proper Body Diagnostic Procedures Manual for testing the Remote Keyless Entry system using a DRB III scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 87 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster (Refer to INSTRUMENT CLUSTER - REMOVAL). Fig. 5 Remote Keyless Entry Module 3. Remove remote keyless entry module from instrument cluster. INSTALLATION 1. Install remote keyless entry module to instrument cluster. 2. Install instrument cluster (Refer to INSTRUMENT CLUSTER - INSTALLATION) 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions Pedal Positioning Module: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 104 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 105 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 106 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 107 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 108 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 109 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Pedal Positioning Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 111 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 112 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 113 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Diagram Information and Instructions > Page 114 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Diagrams > Page 115 Pedal Positioning Module: Description and Operation ADJUSTABLE PEDALS SYSTEM For this vehicle, the adjustable pedal system has no dedicated module controller. The brake, clutch, and accelerator pedal position is controlled by a manual switch located on the instrument panel. ADJUSTABLE PEDALS RELAY The adjustable pedals relay is located in the Integrated Power Module (IPM). The relay, when not activated, supplies fused battery power to the Adjustable Pedals Switch. If the Front Control Module (FCM) receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch. The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 119 Seat Heater Interface Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 120 Seat Heater Control Module: Description and Operation Fig.4 Heated Seat Module HEATED SEAT MODULE The heated seat module is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light-Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty, the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36 °C (96.8 °F), and the High heat set point is about 42 °C (107.6 °F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Diagnosis and Testing Heated Seat System in Heated Systems for flashing LED diagnosis and testing procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 121 Seat Heater Control Module: Testing and Inspection DIAGNOSIS AND TESTING - HEATED SEAT MODULE If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Check the heated seat switch. NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 122 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat, install the heated seat module retaining screws. 4. Re-position the driver seat. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations EBC 125 (RWAL) EBC 325 (ABS) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 127 Electronic Brake Control Module: Diagrams Controller Antilock Brake C1 Controller Antilock Brake C2 (ABS) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 128 Electronic Brake Control Module: Description and Operation Fig.1 Hydraulic Control Unit CONTROLLER ANTILOCK BRAKE (CAB) The Controller Antilock Brake (CAB) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The CAB voltage source is through the ignition switch in the RUN position. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB III scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. TRW EBC 125 CONTROLLER ANTILOCK BRAKE The CAB includes a microprocessor and two solenoids that control the valves that control brake pressure during RWAL braking and circuits that: Monitor the brake switch input to tell whether or not to prepare for possible antilock braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Monitor the wheel speed sensor input to determine when a rear wheel is tending to lock up - Operate the integral hydraulic control unit (HCU) during antilock braking based on comparing the speed sensor to information programmed in memory - Detect RWAL system related problems and take diagnostic action - Able to execute self-tests and output control commands TRW EBC 325 CONTROLLER ANTILOCK BRAKE The CAB includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: Brake switch input is monitored to determine whether or not to prepare for possible ABS braking - Monitor the brake fluid level switch input to tell whether or not the state of the hydraulics has a problem - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the HCU to control braking pressure during ABS braking - Detect ABS system related problems and take diagnostic action - Able to execute self-tests and output control commands Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 129 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the CAB harness connector release and remove connector. 3. Remove the CAB mounting bolts. 4. Remove the pump connector from the CAB. 5. Remove the CAB from the HCU. INSTALLATION NOTE: If the CAB is being replaced with a new CAB is must be reprogrammed with the use of a DRB III. 1. Install CAB to the HCU. 2. Install the pump connector to the CAB. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the CAB and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service Precautions Blower Motor Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Integrated Power Module A/C Compressor Clutch Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 137 Compressor Clutch Relay: Description and Operation The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C Heater mode control switch, the A/C low pressure switch, and the A/C high pressure switch. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 138 Compressor Clutch Relay: Testing and Inspection Fig. 10 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 67.5 to 82.5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 139 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Integrated Power Module Condenser Fan Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination Instrument Panel Control Module: Customer Interest Instruments - Erroneous Indicator lamp Illumination NUMBER: 08-004-03 GROUP: Electrical DATE: March 14, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2129 OR HIGHER, AVAILABLE MARCH 31, 2003 SUBJECT: Flash: Electro Mechanical Instrument Cluster - erroneous indicator lamps OVERVIEW: This bulletin involves selectively erasing and reprogramming the Electro Mechanical Instrument Cluster (MIC) with new software. MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Three conditions have been identified which may be caused by communication errors between the Electro Mechanical Instrument Cluster (MIC) and other electronic modules on the vehicle. 1. An intermittent false "Check Gauges" on diesel engine equipped vehicles. 2. An intermittent false chime and "Low Wash" indicator. A valid "Low Wash" indication will occur for at least a 30 second interval. With this false condition, the chime will occur followed by the "Low Wash" indicator which will last for a half second or less. 3. A "Trans Temp" Indicator on a manual transmissions equipped vehicle. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. EQUIPMENT REQUIRED REPAIR PROCEDURE: NOTE: WHEN FLASH REPROGRAMMING THE MIC, IT IS IMPORTANT THAT NO ELECTRONIC COMMUNICATION OCCURS BETWEEN THE MIC AND OTHER MODULES IN THE VEHICLE. ADDITIONAL STEPS HAVE BEEN ADDED TO THE FLASH PROCEDURE TO PREVENT THIS FROM HAPPENING. 1. Inspect the radio face plate. The radio sales code is printed on the face of the radio. If the vehicle is equipped with an "RAZ" radio, it must be removed from the instrument panel and disconnected to eliminate the possibility of any electronic communication between the radio and the instrument cluster during the flash procedure. 2. Remove the ABS module fuse (# 35) from the fuse panel. This will prevent any communications between the ABS module and the instrument cluster during the flash procedure. 3. Connect a battery charger and set as close to 14 volts charge as possible. 4. Flash the MIC using the TechConnect/MDS2 (Mopar Diagnostic System) and DRBIII(R). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination > Page 152 NOTE: DUE TO THE REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, TCM, BCM, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination Instrument Panel Control Module: All Technical Service Bulletins Instruments - Erroneous Indicator lamp Illumination NUMBER: 08-004-03 GROUP: Electrical DATE: March 14, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2129 OR HIGHER, AVAILABLE MARCH 31, 2003 SUBJECT: Flash: Electro Mechanical Instrument Cluster - erroneous indicator lamps OVERVIEW: This bulletin involves selectively erasing and reprogramming the Electro Mechanical Instrument Cluster (MIC) with new software. MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Three conditions have been identified which may be caused by communication errors between the Electro Mechanical Instrument Cluster (MIC) and other electronic modules on the vehicle. 1. An intermittent false "Check Gauges" on diesel engine equipped vehicles. 2. An intermittent false chime and "Low Wash" indicator. A valid "Low Wash" indication will occur for at least a 30 second interval. With this false condition, the chime will occur followed by the "Low Wash" indicator which will last for a half second or less. 3. A "Trans Temp" Indicator on a manual transmissions equipped vehicle. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. EQUIPMENT REQUIRED REPAIR PROCEDURE: NOTE: WHEN FLASH REPROGRAMMING THE MIC, IT IS IMPORTANT THAT NO ELECTRONIC COMMUNICATION OCCURS BETWEEN THE MIC AND OTHER MODULES IN THE VEHICLE. ADDITIONAL STEPS HAVE BEEN ADDED TO THE FLASH PROCEDURE TO PREVENT THIS FROM HAPPENING. 1. Inspect the radio face plate. The radio sales code is printed on the face of the radio. If the vehicle is equipped with an "RAZ" radio, it must be removed from the instrument panel and disconnected to eliminate the possibility of any electronic communication between the radio and the instrument cluster during the flash procedure. 2. Remove the ABS module fuse (# 35) from the fuse panel. This will prevent any communications between the ABS module and the instrument cluster during the flash procedure. 3. Connect a battery charger and set as close to 14 volts charge as possible. 4. Flash the MIC using the TechConnect/MDS2 (Mopar Diagnostic System) and DRBIII(R). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination > Page 158 NOTE: DUE TO THE REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, TCM, BCM, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation Brake Lamp Relay: Description and Operation DESCRIPTION The exterior lighting system for this model include the following components: ^ Backup Lamps ^ Brake Lamps ^ Daytime Running Lamps ^ Front Fog Lamps ^ Hazard Warning Lamps ^ Headlamps ^ Park Lamps ^ Turn Signal Lamps Other components of the exterior lighting system for this model include: ^ Backup Lamp Switch ^ Brake Lamp Switch ^ Front Control Module ^ Front Fog Lamp Relay See: Relays and Modules - Power and Ground Distribution/Relay Box ^ Hazard Switch ^ Multi-Function Switch ^ Park Lamp Relay See: Relays and Modules - Power and Ground Distribution/Relay Box ^ Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switches provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Integrated Power Module Fog Lamp Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 166 Fog/Driving Lamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 167 Fog/Driving Lamp Relay: Description and Operation Fig.7 ISO Micro Relay The front fog lamp relay is located in the Power Distribution Center (PDC) See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID in the engine compartment of the vehicle. The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front fog lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front fog lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front fog lamp relay include: - Common Feed Terminal - The common feed terminal (30) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a front fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is not connected in this application. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 168 Fog/Driving Lamp Relay: Testing and Inspection Fig.8 ISO Micro Relay The front fog lamp relay is located in the Power Distribution Center in the engine compartment. See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID. Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the front fog lamp relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRBIII scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 169 Fog/Driving Lamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover for the Power Distribution Center (PDC). 3. Remove the front fog lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. Position the front fog lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the front fog lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the front fog lamp relay until the terminals are fully seated in the PDC. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams Horn Relay: Diagrams Integrated Power Module Horn Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 173 Horn Relay: Description and Operation HORN RELAY The Horn Relay, which is internal to the Integrated Power Module (IPM), is controlled by the Front Control Module (FCM) through PCI bus messages from the instrument cluster. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Information Bus See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). Under normal operating conditions, if the horn is activated for more than 30 seconds, the FCM will automatically deactivate the horn to prevent damage. The FCM will reactivate control of the relay after a 25 second cool-down period. The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTC's. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Integrated Power Module Park Lamp Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 177 Parking Lamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 178 Parking Lamp Relay: Description and Operation PARK LAMP RELAY Fig.16 ISO Micro Relay The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the park lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The park lamp relay terminals are connected to the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of the headlamp low beam relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the park lamps through the park lamp relay output circuit and provides ground to the park lamps when the relay is de-energized, and battery current to the park lamps whenever the relay is energized. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 179 Parking Lamp Relay: Testing and Inspection Fig.17 ISO Micro Relay The park lamp relay is located in the Power Distribution Center (PDC). Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the park lamp relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRBIII scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 180 Parking Lamp Relay: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION 1. Position the park lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the park lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the park lamp relay until the terminals are fully seated in the PDC. 4. Install the PDC cover. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams Trailer Lighting Relay: Diagrams Trailer Tow Left Turn Relay Trailer Tow Right Turn Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation Micro ISO Relay: Description and Operation Fig.9 DR ISO Micro Relay A micro-relay is a conventional International Standards Organization (ISO) micro relay (Fig. 9). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. Relays cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. A micro-relay is an electromechanical switch that uses a low current input from one source to control a high current output to another device. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation > Page 188 Micro ISO Relay: Testing and Inspection DIAGNOSIS AND TESTING Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. MICRO-RELAY 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 67.5 - 82.5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III® scan tool to perform further testing. Refer to the appropriate diagnostic information. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for battery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) circuit to the integrated power module fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required. 4. The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required. 5. The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continuity to ground at all times. If not OK, repair the open ground circuit to ground as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation > Page 189 Micro ISO Relay: Service and Repair MICRO RELAY REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Align the micro-relay terminals with the terminal cavities in the receptacle. 2. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Description and Operation Mini ISO Relay: Description and Operation Fig.8 ISO Relay A relay (Fig. 8) is an electromechanical device that switches fused battery current to a electrical component when the ignition switch is turned to the Accessory or Run positions, or when controlled by a electronic module. The relays are located in the integrated power module. The relay is a International Standards Organization (ISO) relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. A relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor is connected in parallel with the electromagnetic coil in the relay and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Description and Operation > Page 193 Mini ISO Relay: Testing and Inspection DIAGNOSIS AND TESTING RELAY The relays are located in the integrated power module. For complete circuit diagrams, refer to Wiring Diagrams. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 60.7 - 80.3 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for battery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) circuit to the integrated power module fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required. 4. The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required. 5. The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continuity to ground at all times. If not OK, repair the open ground circuit to ground as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Description and Operation > Page 194 Mini ISO Relay: Service and Repair RELAY REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Position the relay to the proper receptacle. 2. Align the relay terminals with the terminal cavities in the receptacle. 3. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 4. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams Power Distribution Module: Diagrams Integrated Power Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 198 Integrated Power Module (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 199 Integrated Power Module FCM Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 200 Integrated Power Module C1 Integrated Power Module C2 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 201 Integrated Power Module C3 Integrated Power Module C4 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 202 Integrated Power Module C5 Integrated Power Module C6 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Page 203 Integrated Power Module C7 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module INTEGRATED POWER MODULE Fig.1 DR Integrated Power Module The Integrated Power Module (IPM) (Fig. 1) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery on this model. The power distribution center mates directly with the Front Control Module (FCM) to form the Integrated Power Module Fuse and Relay Center. The power distribution center (PDC) is a printed circuit board based module that contains fuses and relays, while the front control module contains the electronics controlling the integrated power module and other functions. This integrated power module connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The integrated power module provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic integrated power module housing includes a base and cover. The integrated power module cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This integrated power module housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the integrated power module assembly are broken down into the following components: the Power Distribution Center (PDC), the integrated power module cover, the Front Control Module (FCM) and the Integrated Power Module Assembly which includes the power distribution center, the cover and FCM. Refer to the Front Control Module in the Electronic Control Module section for information on the front control module. All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Refer to the Wiring section for complete integrated power module circuit schematics. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 206 Power Distribution Module: Description and Operation Front Control Module FRONT CONTROL MODULE DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. On this model the integrated power module must be positioned aside in order to access the front control module. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The integrated power module connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit (J1850). OPERATION As messages are sent over the PCI bus circuit, the front control module reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the Front Control Module: Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the Front Control Module: B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 207 Power Distribution Module: Testing and Inspection DIAGNOSIS AND TESTING - FRONT CONTROL MODULE The front control module is a printed circuit board based module with a on-board micro-processor. The front control module interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus (J1850). In order to obtain conclusive testing the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the front control module must be checked. All PCI (J1850) communication faults must be resolved prior to further diagnosing any front control module related issues. The front control module was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III. The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III scan tool and the proper Body Diagnostic Procedures manual. Before any testing of the front control module is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module B+ terminal. Remove the B+ cable from the integrated power module. 3. Disconnect the gray connector from the integrated power module. Fig.2 Dr Integrated Power Module 4. Remove the integrated power module retaining bolt and screw (Fig. 2). Fig. 3 Removing Integrated Power Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 210 5. Grasp the integrated power module with two hands and slide the assembly in the direction shown (Fig. 3) to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 6. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the module assembly. Be certain to pull the connectors straight off. 7. Position the integrated power module on a bench and remove the four front control module retaining screws. 8. Disconnect the front control module by pulling it straight off the integrated power module. INSTALLATION 1. Connect the front control module by pushing it straight on the integrated power module electrical receptacle. 2. Install the four front control module retaining screws. Torque to 30 ± 5 in. lbs.. Fig.4 Integrated Power Module Electrical Connections NOTE: Integrated power module electrical connectors are color coded to ease location reference (Fig. 4). 3. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the module assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 211 Fig.5 Integrated Power Module Mounting Tabs 4. Grasp the integrated power module with two hands and install the assembly on the battery tray (Fig. 5). 5. Install the integrated power module retaining bolt and screw. 6. Connect the gray connector on the integrated power module housing. 7. Install the B+ terminal cable and nut on the integrated power module B+ terminal. Snap the cover in place. 8. Connect the negative and positive battery cables. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 212 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the integrated power module from the engine compartment. 3. Remove the front control module retaining screws. 4. Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle. INSTALLATION 1. Install the front control module on the integrated power module assembly by pushing the 49-way electrical connector straight in. 2. Install the front control module retaining screws. Torque the screws to 7 in. lbs. 3. Install the integrated power module. 4. Connect the positive and negative battery cables. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation ISO RELAY Fig.8 ISO Relay A relay (Fig. 8) is an electromechanical device that switches fused battery current to a electrical component when the ignition switch is turned to the Accessory or Run positions, or when controlled by a electronic module. The relays are located in the integrated power module. The relay is a International Standards Organization (ISO) relay Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. A relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor is connected in parallel with the electromagnetic coil in the relay and helps to dissipate voltage spikes that are produced when the coil is de-energized. MICRO ISO RELAY Fig.9 DR ISO Micro Relay A micro-relay is a conventional International Standards Organization (ISO) micro relay (Fig. 9). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation > Page 216 plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. Relays cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. A micro-relay is an electromechanical switch that uses a low current input from one source to control a high current output to another device. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation > Page 217 Power Distribution Relay: Testing and Inspection DIAGNOSIS AND TESTING RELAY The relays are located in the integrated power module. For complete circuit diagrams, refer to Wiring Diagrams. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 60.7 - 80.3 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay MICRO-RELAY 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 67.5 - 82.5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III® scan tool to perform further testing. Refer to the appropriate diagnostic information. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for battery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) circuit to the integrated power module fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required. 4. The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required. 5. The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continuity to ground at all times. If not OK, repair the open ground circuit to ground as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Power Distribution Relay: Service and Repair Relay REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Position the relay to the proper receptacle. 2. Align the relay terminals with the terminal cavities in the receptacle. 3. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 4. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay > Page 220 Power Distribution Relay: Service and Repair Micro-Relay REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Align the micro-relay terminals with the terminal cavities in the receptacle. 2. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 224 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 225 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 226 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 227 Relay Box: Diagrams Integrated Power Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 228 Integrated Power Module (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 229 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 230 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 231 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 232 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 239 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 240 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Body Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Body Control Module: Electrical Diagrams Airbag System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Premium Audio System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Base Audio System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 Remote Radio Controls Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 PCI Bus Communication Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 PCM Communication - JTEC PCM Communication - NGC Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 ECM Communication - Diesel Door Ajar System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 Heated Mirror System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Exterior Lights Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Heating-A/C System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Horn System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Instrument Cluster Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Overhead Console Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Power Door Locks Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Vehicle Theft Security System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Wipers Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 279 Body Control 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the "body" system are: Airbag - Audio (with amplifier on premium systems) - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Heating and A/C - Horn - Instrument Cluster - Interior Lighting - Memory Seat - Overhead Console - Power Door Lock/RKE - Power windows - Vehicle theft security system (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION The body system on the 2003 DR consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the communication section of this general information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 282 Body Control Module: Description and Operation Functional Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjuction with the seat belt system. On some models the ACM supports Seat Belt Tensioners, Passenger Airbag Off Switch, and others Side Impact Airbag Control Modules. It may be necessary to use the DRBIII to reconfigure the ACM to the vehicle equipment. 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 via the PCI bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6 - 8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6 - 8 seconds, then goes off, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. The 2003 DR will have two Airbag Control Modules. Each ACM is specifically calibrated for one body type, light duty or heavy duty. To determine the body types the ACM monitors the PCI Bus for a message containing the complete VIN. The ACM uses the 6th digit of the VIN to identify the heavy duty or light duty vehicle. The 6th digit of the VIN will be a number 1 for light-duty vehicle and a 2, 3 or 4 for heavy-duty vehicle. If the PCI Bus VIN message 6th character matches the ACM body type, the VIN will be stored within 5.6 seconds after ignition on. After the VIN is stored, the ACM verifies PCI Bus VIN message within 2.6 seconds after the ignition is turned on. If two valid matching PCI Bus VIN messages are not received within 5.6 seconds the ACM will set a Missing Original VIN DTC. If the ACM and PCM module types, 6th character of the VIN, light-duty or heavy-duty do riot match the Calibration Mismatch DTC will be set. CAUTION: Therefore, the practice of exchanging (swapping) airbag control modules, instrument clusters, powertrain control modules and other electronic modules In this vehicle with those removed from another vehicle must always be avoided. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 283 WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Passenger Airbag On-Off Switch The Passenger Airbag On-Off Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the off position and for 2 seconds at ignition on for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the On-Off switch with the ignition on. The ACM continuously monitors the resistance of the Passenger Airbag On/Off Switch circuits to identify the switch position and provide circuit diagnostics. The On/Off switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the On/Off switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned on by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6 - 8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact Will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Side Impact Airbag Control Module (SIACM) Supplemental driver and front passenger curtain airbags provide side impact protection for the front and rear seat occupants. Each curtain airbag has its own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just below the seat belt retractor. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. The results of the system test are transmitted on the PCI Bus to the ACM once each second. If the warning lamp status message from either SIACM contains a lamp on request, the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned on. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Curtain Airbags The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 284 the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 degrees C (200 degrees F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. SPECIAL TOOLS Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRBIII. 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 within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned off. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as in active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 285 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. Maintain a safe distance from all airbags while performing the following inspection. 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. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII. When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: - On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. - On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Remote Radio Controls These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRBIII. The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The 03 DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition on, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition on, the DRBIII should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRBIII that will help in diagnosing audio system problems. The DRBIII can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRBIII can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRBIII audio system diagnostics can determine the nature of the problem. Diagnostic tests the Amplifier can perform through the DRBIII: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Communication COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 286 The following modules are used on this vehicle: - Front Control Module - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - A/C Heater Control Module - Powertrain Control Module (gas and diesel) - Engine Control Module (diesel only) - Radio - Amplifier (if equipped) - Transmission Control Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at 0 volts when no modules are transmitting and is pulled up to about 7 1/2 volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 287 message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII lab scope. The 12 V square wave selection on the 20 volt scale provides a good view of the bus activity. Voltage on the bus should pulse between 0 and about 7 1/2 volts. Refer to the diagram for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the ECM/PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII may display "BUS + SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: The 2003 DR will have different controller configurations based on the engine, transmission and electronic throttle control combinations. You will need to identify which controller is being used on the vehicle that requires service. The 3.7L engine will use a JTEC Powertrain controller with a Transmission Control module. The 5.7L engine will use a new NGCII Powertrain controller (PCM) with EATX Transmission controller. - The NGCII controller is not the same as the NGCI controller. The NGCI controller combines the engine and transmission controls into a single module and is used on the 4.7L engine. The NGCII controller will incorporate the engine and electronic throttle controls into a single module, the transmission functions will be controlled by a separate Transmission Control Module. NGC Controller Some of the changes you will see are several new Diagnostics Trouble Codes and supporting diagnostic procedures which reflect the new combined module technology. The PCM will have four color coded connectors, C1 through C4, (C1-BLK, C2-GRAY, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins. Two new tools are used for probing and repairing the new PCM connectors. The Terminal Remover Miller Tool # 3638, and Diagnostic Pinout box Miller Tool # 8815. Miller Tool # 3638 is designed to release the terminals from the PCM harness connectors. You must use the Miller tool # 3638 to release the harness connector terminals or harness connector or terminal damage will occur. Miller tool # 8815 was designed for probing the PCM harness connectors. You must use Miller tool # 8815 for probing the PCM terminals or damage to the terminal will occur resulting in a poor terminal to pin connection. There are also new Verification tests and module replacement procedures for the PCM. Compass/Mini-Trip Computer COMPASS MINI-TRIP COMPUTER (CMTC) When equipped, the Compass/Mini Trip Computer (CMTC) is located in the overhead console. The CMTC supplements the standard vehicle instrumentation. The CMTC uses a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, and elapsed ignition on time. If equipped, the CMTC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink. The CMTC function buttons are labeled C/T, RESET, STEP and US/M. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC display information is received over the PCI bus. The CMTC sends and receives data over the PCI bus, communicating with the FCM (3.7L, 5.9L, and 8.0L), NGC (4.7L and 5.7L), or PCM, and the Instrument Cluster. Vehicle Information Display The CMTC provides the following functions: Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip Odometer The CMTC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 288 Overhead Console section for problems related to the CMTC. The CMTC receives the following messages from the Instrument Cluster: Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty The CMTC receives the following message from the PCM: Vehicle Speed US/M Button The US/M button is used to toggle the display between English and Metric measurement units. Step Button The STEP Button can be used in one of the following ways: 1. To sequentially select one of 4 displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. Reset Button The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed and the CMTC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. The CMTC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from Off to On will enter the CMTC into the self-diagnostic mode. Compass/Temperature (C/T) Button Actuating the Compass/Temperature Button (C/T) will cause the CMTC to display the compass and temperature information. This function will operate from another traveler display. The CMTC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC module internally senses and calculates the compass direction. Traveler Display Functions Using the STEP button will change the CMTC between modes of operation and display the appropriate information according to data received from the PCI Bus. Compass Operation Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 289 readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. Setting Magnetic Zone Variance Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: The ignition switch must be in the On position and the CMTC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC returns to normal operation. Compass Calibration The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CMTC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance." - The ignition switch must be in the On position and the CMTC display must not be blank. - Press the C/T button to view the Compass/Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. If the compass appears blank, unable to be calibrated, or the compass displays false indications, the vehicle must be demagnetized. Refer to Compass Demagnetizing Procedure. Self-Check Diagnostics The CMTC is capable of performing a diagnostic self check on its internal functions. CMTC diagnostics may be performed using a DRBIII or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2 - 4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC must be replaced. Ambient Temperature Sensor The ambient air temperature is monitored by the FCM or the NGC and displayed by the CMTC. For 3.7L, 5.9L, and 8.0L equipped vehicles, the FCM Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 290 receives a hardwire input from the ambient temperature sensor (ATS). For 4.7L and 5.7L equipped vehicles, the NGC receives the hardwire input from the ATS. The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM or NGC. The resistance in the ATS changes as the outside temperature rises or falls. The FCM or NGC senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM or NGC is programmed to correspond to a specific temperature. The FCM or NGC stores and filters the ambient temperature data and transmits this data to the CMTC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Ambient Temperature Sensor Fault Codes The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM or the NGC, and the CMTC display. If the CMTC display indicates 54 °C (130 °F) or the ATS sense circuit is shorted to ground, the temp display will be 54 °C (130 °F) to indicate a SHORT circuit condition. If the CMTC display indicates -40 °C (-40 °F) or the ATS sense circuit is open, the temp display will be -40 °C (-40 °F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTCs will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures. If the CMTC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC temperature display is inoperative or incorrect, replace the FCM or NGC as required. Ambient Temperature Sensor Test 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: Temperature Sensor Resistance 0 °C (32 °F) 29.33 - 35.99 Kilohms 10 °C (50 °F) 17.99 - 21.81 Kilohms 20 °C (68 °F) 11.37 - 13.61 Kilohms 25 °C (77 °F) 9.12 - 10.86 Kilohms 30 °C (86 °F) 7.37 - 8.75 Kilohms 40 °C (104 °F) 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. Electronic Vehicle Information Center (EVIC) When equipped, the Electronic Vehicle Information Center is located in the overhead console. The EVIC performs all of the same functions as a Compass Mini-Trip Computer (CMTC). The EVIC also provides additional driver information, warnings; an interface to enable and disable vehicle programmable features and display memory system messages. The EVIC is integrated with the Universal Garage Door Opener (UGDO) known as HomeLine. The EVIC function buttons are labeled MENU, STEP, CAL, and RESET. All of the EVIC features are the same as the CMTC, with the following additional features: WARNING MESSAGES: when the appropriate conditions exist, the EVIC displays the following warning messages and symbols. Each message is accompanied by a series of beeps. TURN SIGNALS ON (with graphic) - TURN SIGNAL OUT (with graphic) - PERFORM SERVICE - DOOR OPEN (One or more, with graphic) - WASHER FLUID LOW (with graphic) - RKE FOB BATTERY LOW - LAMP OUT (with graphic) for Headlamp, Tarn Lamp, and Brake Lamp CUSTOMER PROGRAMMABLE FEATURES: Press the MENU button to select one of the following displays: LANGUAGE (Press STEP button to select one of 5 languages) - US or METRIC (Press STEP button to toggle between US or Metric units) - AUTO DOOR LOCKS (Press STEP button to select "Yes" or "No"). - AUTO UNLOCK ON EXIT (Press STEP button to select "Yes" or "No"). - REMOTE UNLOCK DRIVER'S DOOR 1st (Press STEP button to select) - SOUND HORN ON LOCK (Press STEP button to select) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 291 - FLASH LIGHTS ON LOCK/UNLOCK ? (Press STEP button to select "Yes" or "No"). - HEADLAMP DELAY (Press STEP button to select desired delay) - SERVICE INTERVAL (Press STEP button to select distance internals) - RESET SERVICE DISTANCE (Press STEP button to select "Yes" or "No"). - TRAINING REMOTE KEYLESS ENTRY FOBS (Press STEP button to select "Yes" or "No"). For complete details of the EVIC operation and Customer Programmable Features, refer to the Owner Manual. All other EVIC features are the same as the CMTC, for information regarding Outside Temperature, Compass Calibration and Zone Variance, refer to the Compass/Mini-Trip Computer information in this section. Refer to the symptom list in the Overhead Console section for problems related to this EVIC. HomeLink Universal Transmitter If equipped, the HomeLink Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink transmitter channel button is being pressed. The HomeLink can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink buttons are marked with one, two, or three dots. For complete information, refer to Universal Transmitter. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRBIII will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state or the DRBIII will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRBIII displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRBIII displays the switch state as OPEN, it indicates an open door ajar circuit. Electrically Heated Systems ELECTRICALLY HEATED SYSTEMS Heated Mirror Relay A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTCs. Exterior Lighting System EXTERIOR LIGHTING SYSTEM The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the head-lamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 5 minutes, the FCM will turn the exterior lamps off. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module FRONT CONTROL MODULE The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hard-wired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds: Brake lights - Headlamp power - Turn signals (front & rear) - Windshield washer pump motor Relay Controls Adjustable pedals relay (when equipped) - Fog lamp relay (when equipped) - Horn relay - Park lamp relay - Trailer tow relays - Wiper on/off relay - Wiper high/low relay Electrical Inputs Module battery supply - Power ground Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 292 - Ignition switch RUN or START position status - PCI bus - Wiper park switch - Washer fluid level switch - Ambient Temperature sensor - Battery (+) connection detection CONTROLLED POWER FEEDS Headlamp Power The headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power on or off (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching off the low side circuit. If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. RELAY CONTROLS Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch. The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTCs. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn on the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTCs. Park Lamp Relay The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/low relay. The relay switches power between the low speed and high speed of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper On/Off Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper on/off relay. The wiper on/off relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. Electrical Inputs Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 293 Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 volt input to inform the FCM of the ignition switch status for related FCM functions. PCI Bus Approximately 7.5 volt input to allow the FCM to communicate with other modules on the PCI bus. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Battery (+) Connection Detection 12 volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Heating & A/C System HEATING & A/C SYSTEM System Availability Depending on the model, either a Single-Zone or Dual-Zone HVAC system is available in these vehicles. System Controls The Heater Control Module: is fully addressable with the DRBIII. - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror operation (if equipped). - controls electronic door actuator operation. The A/C-Heater Control Module: - is fully addressable with the DRBIII. - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). - controls heated mirror operation (if equipped). - controls electronic door actuator operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C-Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C-Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electronic blend door actuator. - two, two-wire electronic mode door actuators. - one, two-wire electronic recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electronic blend door actuators. - two, two-wire electronic mode door actuators. - one, two-wire electronic recirculation door actuator. System Revisions The 2003 DR, HVAC system remains mostly carry over from 2002. Revisions to the 2003 HVAC system include: a heater only option for select vehicles - a change in A/C mode switch status indicator operation when performing the A/C Cooldown test. Refer to The A/C Cooldown Test under System Diagnostics for more information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 294 - a change in EBL mode switch status indicator operation when performing the HVAC Door Recalibration. Refer to The HVAC Door Recalibration Function under System Diagnostics for more information. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTCs) DTCs are displayed by the DRBIII. - Active DTCs are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTCs are those which occurred in the system since the A/C-Heater Control Module received the last ■clear diagnostic info" message. The A/C Cooldown Test: is actuated with the DRBIII. - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7 °C (55 °F). - will pass if the evaporator temperature drops 6.7 °C (20 °F) within two minutes of starting the test. - faults display on the DRBIII as test messages only after running the test. - faults will not display on the DRBIII as Diagnostic Trouble Codes. - will cause the A/C mode switch status indicator to flash while the test is running. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The HVAC Door Recalibration function: is actuated with the DRBIII. - monitors for door span faults. - faults display on the DRBIII as test messages only after running the test. - faults will not display on the DRBIII as Diagnostic Trouble Codes. - will cause the EBL mode switch status indicator to flash while the test is running. If the test fails, the status indicator will continue to flash until either the test returns passed or the ignition key is cycled. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: is actuated with the DRBIII. - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII as test messages only after running the test. - faults will not display on the DRBIII as Diagnostic Trouble Codes. When Performing The Actuator Circuit Test CAUTION: To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. - The DRBIII can display up to three Actuator Circuit Test messages at a time After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. The Short Tho Complex message: - indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. -Messages displaying: - XXX Driver/Circuit Shorted to Ignition Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as well as shorted to ground indicates that two actuator driver circuits are shorted together. -When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster INSTRUMENT CLUSTER The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a vacuum fluorescent (VF) display for the PRNDL, Total and Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 295 Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTCs, communicate on the PCI bus, display engine information, and display certain inputs using the DRBIII. The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: Audible Warnings - Brake Lamp Control - Brake Transmission Shift Interlock (BTSI) - Cargo Lamp Control - Central Locking - Door Lock Inhibit - Enhanced Accident Response - Exterior Lighting Control - Exterior Lighting Fail-safe - Heated Seat Control - Horn Control - Interior Lamp Control - Interior Lamps - Enhanced Accident Response - Interior Lamps Load Shedding - Lamp Out Indicator Control - Panel Lamps Dimming Control - Parade Mode - Power Locks - Remote Keyless Entry (RKE) - Remote Radio Switch Interface - Rolling Door Locks - Turn Signal and Hazard Warning Lamp Control - Vacuum Fluorescent Display Synchronization - Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules In the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. Diagnostic Self Test The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRBIII. During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine speed greater than 0 (zero) rpm will stop the self test. Interior Lighting INTERIOR LIGHTING The Instrument Cluster controls the Interior/Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned on or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn on the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 296 switch remains active, the request will be ignored until the switch transitions back to off. The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. Automatic Door Locks The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 mph (24 kmh), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRBIII. Central Locking/Unlocking The Instrument Cluster will lock all doors when the cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from the driver cylinder lock switch, it will unlock only that door. If the Instrument Cluster receives a second command within a 5 second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. Door Lock Inhibit When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. Enhanced Accident Response Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: Immediately disable the power door lock output - Unlock all doors by activating the door unlock output for approximately 300 milliseconds. - After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. REMOTE KEYLESS ENTRY The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keyfob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: Arm the Vehicle Theft Security System (if equipped and all conditions are met). - Turn off the illuminated entry feature. - Activate the door lock motors. - Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: Disarm the Vehicle Theft Security System (if equipped and previously set). - Activate the illuminated entry and cargo lamp. - Activate the driver door unlock motor (if customer programmed for driver door only unlock). - Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System VEHICLE THEFT SECURITY SYSTEM The Instrument Cluster controls the Vehicle Theft Security System (VTSS). When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. The Instrument Cluster will enable the VTSS feature once it has received PCI bus messages from the Sentry Key Immobilizer Module and has also detected the driver cylinder lock switch being cycled to the lock/unlock position. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for 16 seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition on with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will time-out and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRBIII. The DRBIII is also useful for a customer complaint of the alarm going Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 297 off with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers WINDSHIELD WIPERS/WASHERS The Instrument Cluster controls the wiper/washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers on. Two relays, the High/Low relay and the On/Off relay also control the wipers. Both are located in the PDC or Integrated Power Module. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures A/C Status Indicator Flashing Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run A/C Status Indicator Will Not Illuminate (w/o EBL Switch) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 300 Test 1 SYMPTOM A/C STATUS INDICATOR WILL NOT ILLUMINATE -- A/C - HEATER CONTROL WITHOUT EBL SW POSSIBLE CAUSES - HVAC door recalibration failed - A/C - heater control module A/C-Heater Control Illumination Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 301 Test 4 SYMPTOM A/C-HEATER CONTROL ILLUMINATION INOPERATIVE POSSIBLE CAUSES - Check for instrument cluster (MIC) DTCs - Inoperative bulb(s) - A/C-Heater control module - Panel lamps driver circuit open - Instrument cluster All Gauges Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 302 Test 4 - 7 Test 8 SYMPTOM Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 303 ALL GAUGES INOPERATIVE POSSIBLE CAUSE - No response - PCI bus - PCI bus - powertrain control module - PCI bus - instrument cluster - Fused ignition switch output circuit (unlock/run) short to ground - Instrument cluster ground circuit open - Fused ignition switch output (run/start) circuit open - Fused ignition switch output (run/start) circuit short to ground - Fused ignition switch output (unlock/run) circuit open - Instrument cluster Am/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Amplifier Pretest Test 1 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 304 SYMPTOM AMPLIFIER PRETEST POSSIBLE CAUSE - Amplifier pretest - No fault message displayed Any PCI BUS Indicator Inoperative Test 1 - 4 SYMPTOM ANY PCI INDICATOR INOPERATIVE POSSIBLE CAUSE - Indicator message not received - No response - instrument cluster - No response - PCI bus - No response - PCI bus - powertrain control module - Instrument cluster Any Station Preset Switch Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 305 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Average Fuel Economy Inaccurate or Wrong Test 1 SYMPTOM AVERAGE FUEL ECONOMY INACCURATE OR WRONG POSSIBLE CAUSE - CMTC / EVIC Balance Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 306 Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Blend/Mode/Recirc Door Operation Improper (Dual Zone) Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 307 Test 4 - 6 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 308 Test 7 - 8 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER--DUAL-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper (Single Zone) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 309 Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 310 Test 4 - 6 Test 7 SYMPTOM Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 311 BLEND/MODE/RECIRC DOOR OPERATION IMPROPER--SINGLE-ZONE POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTCs - Check for HVAC door recalibration fault messages - Mode door actuator(s)/linkage(s)/door(s) - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Blower Motor Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 312 Test 4 - 8 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 313 Test 9 - 10 SYMPTOM BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - IPM FUSE # 4 - Blower motor feed circuit shorted to ground - Fused B(+) shorted to ground - Blower motor shorted to ground - Blower motor - Blower motor high driver circuit open - Ground circuit open - A/C - heater control module open - Blower motor feed circuit open - Fused B(+) circuit open - Ignition switch open Blower Motor Speeds Incorrect Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 314 Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 315 Test 4 - 6 SYMPTOM BLOWER MOTOR SPEEDS INCORRECT POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - A/C - heater control module - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed Brake Warning Indicator Always On Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 316 Test 1 - 3 Test 4 - 5 SYMPTOM BRAKE WARNING INDICATOR ALWAYS ON POSSIBLE CAUSE - Brake fluid level switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 317 - Brake fluid level switch sense circuit short to ground - Park brake switch - Park brake switch sense circuit short to ground - Control module - Instrument cluster Brake Warning Indicator Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 318 Test 4 - 7 SYMPTOM BRAKE WARNING INDICATOR INOPERATIVE POSSIBLE CAUSE - Brake fluid level switch ground circuit open - Brake fluid level switch - Brake fluid level switch sense circuit open - Park brake switch - Park brake switch sense circuit open - Control module - Instrument cluster CD Eject Switch Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 319 Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSE - Actuate chime with DRBIII - Instrument cluster - chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 320 Test 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSE - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster CMTC or EVIC Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 321 Test 1 - 3 SYMPTOM CMTC OR EVIC INOPERATIVE POSSIBLE CAUSE - Fused B(+) circuit open - Fused ignition switch output circuit open - Ground circuit open - Compass/Mini-Trip computer / EVIC Compass Test Failure Test 1 SYMPTOM COMPASS TEST FAILURE POSSIBLE CAUSE - Compass/Mini-Trip computer Distance to Empty Inaccurate or Wrong Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 322 Test 1 SYMPTOM DISTANCE TO EMPTY INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSE - CMTC / EVIC Elapsed Ignition on Time Inaccurate or Wrong Test 1 SYMPTOM ELAPSED IGNITION ON TIME INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSE - CMTC / EVIC Temperature Display Inaccurate or Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 323 Test 1 - 2 SYMPTOM TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE POSSIBLE CAUSE - Ambient temperature sensor compass/mini-trip computer / EVIC EBL Status Indicator Flashing Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 324 Test 1 - 2 Test 3 SYMPTOM EBL STATUS INDICATOR FLASHING TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Equalizer Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 325 Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure FF/RW Switch Inoperative Test 1 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 326 This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Horns Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 327 Test 4 - 8 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 328 Test 9 - 11 SYMPTOM HORNS INOPERATIVE POSSIBLE CAUSES - Horn ground circuit open - Horn relay output circuit open - Horns - Instrument cluster - DTC present - Clockspring - Front control module - Fuse # 45 - Horn switch - Horn switch ground - Horn switch sense open - Integrated power module Hour/Minute Switches Inoperative Test 1 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 329 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure HVAC System Test Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 330 Test 3 - 4 SYMPTOM HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM - Check for HVAC related DTCs in the PCM - Check for active HVAC DTCs and system test fault messages - Check for HVAC related DTCs in the PCM - Manual A/C system test Key In Ignition and Driver's Door Open Chime Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 331 Test 1 - 3 Test 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSE - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status One Gauge Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 332 Test 1 - 2 SYMPTOM ONE GAUGE INOPERATIVE - GAS ENGINES POSSIBLE CAUSE - Powertrain control module DTCs - Intermittent condition - Instrument cluster Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Alarm Trips On Its Own Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 333 Test 1 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSE - DRB display last VTSS cause - Intermittent condition All Door Locks Inoperative Test 1 - 3 SYMPTOM ALL DOOR LOCKS INOPERATIVE POSSIBLE CAUSE - DTC present - Fuse # 22 open - Fuse B+ circuit open - Instrument cluster - open circuit Automatic (Rolling) Door Locks Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 334 Test 1 - 4 SYMPTOM AUTO (ROLLING) DOOR LOCKS INOPERATIVE POSSIBLE CAUSE - Check the door ajar switch status - With the DRB check for PCM DTC'S - With the DRB enable auto door locks - Instrument cluster - auto door locks fail Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 335 Test 4 SYMPTOM CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSE - DTC present - Cylinder lock switch ground open - Cylinder lock switch mux circuit open - Cylinder lock switch open - Instrument cluster - open Cylinder Lock Switch Will Not Arm and/or Disarm Alarm Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 336 Test 4 SYMPTOM CYLINDER LOCK SWITCH WILL NOT ARM AND/OR DISARM ALARM TEST NOTE This symptom is diagnosed using the test CYLINDER LOCK SWITCH INOPERATIVE. POSSIBLE CAUSE - DTC present - Cylinder lock switch ground open - Cylinder lock switch mux circuit open - Cylinder lock switch open - Instrument cluster - open Door Lock Inhibit Inoperative Test 1 SYMPTOM DOOR LOCK INHIBIT INOPERATIVE POSSIBLE CAUSE - Chime inoperative - Instrument cluster - door lock inhibit inoperative Left Doors Fail to Lock and Unlock - Quad Cab Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 337 Test 1 - 4 Test 5 SYMPTOM LEFT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSE - DTC present - Instrument cluster - door lock driver left doors open - Door unlock driver left doors wire open - Door lock driver left doors wire open - Door lock motor One Door Lock Motor Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 338 Test 1 SYMPTOM ONE DOOR LOCK MOTOR INOPERATIVE POSSIBLE CAUSE - Door lock motor open - Check door lock motor circuit Right Doors Fail to Lock and Unlock - Quad Cab Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 339 Test 1 - 4 Test 5 SYMPTOM RIGHT DOORS FAIL TO LOCK AND UNLOCK - QUAD CAB POSSIBLE CAUSE - DTC present - Instrument cluster - door lock driver right doors open - Door unlock driver right doors wire open - DOOR LOCK DRIVER RIGHT DOORS WIRE OPEN - Door lock motor RKE Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 340 Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 341 Test 4 - 6 SYMPTOM RKE INOPERATIVE POSSIBLE CAUSE - Test transmitter with tester - RKE transmitter not programmed - DTC present - Transmitter not programmed - Substitute transmitter - Remote keyless entry module - RKE open - RKE module Right Rear Door Ajar Circuit Open Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 342 Test 1 - 4 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSE - Right rear door ajar switch - Right rear door ajar switch ground circuit open - Right rear door ajar switch sense circuit open - Instrument cluster - right rear door ajar open Right Rear Door Ajar Circuit Shorted to Ground Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 343 Test 1 - 3 SYMPTOM RIGHT REAR DOOR AJAR CIRCUIT SHORT TO GROUND POSSIBLE CAUSE - Right rear door ajar switch shorted to ground - Right rear door ajar switch sense circuit shorted to ground - Instrument cluster - right rear door ajar shorted PWR Switch Inoperative Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Scan Switch Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 344 Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Seat Belt Warning Indicator Always Off Test 1 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS OFF POSSIBLE CAUSE - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always Off - Standard Cab Test 1 SYMPTOM Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 345 SEAT BELT WARNING INDICATOR ALWAYS OFF - STANDARD CAB POSSIBLE CAUSE - Seat belt switch sense circuit short to ground - Instrument cluster Seat Belt Warning Indicator Always On Test 1 - 3 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON POSSIBLE CAUSE - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seat Belt Warning Indicator Always On - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 346 Test 1 - 3 Test 4 - 5 SYMPTOM SEAT BELT WARNING INDICATOR ALWAYS ON - STANDARD CAB POSSIBLE CAUSE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 347 - Fused ignition switch output (run-acc) circuit open - Seat belt tensioner reducer - Seat belt switch - Seat belt switch ground circuit open - Seat belt switch sense circuit open - Instrument cluster Seek Switch Inoperative Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Tape Eject Switch Inoperative Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 348 Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Trip Odometer Inaccurate or Wrong Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 349 Test 1 SYMPTOM TRIP ODOMETER INACCURATE OR WRONG TEST NOTE This symptom is diagnosed using the test AVERAGE FUEL ECONOMY INACCURATE OR WRONG. POSSIBLE CAUSE - CMTC / EVIC Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSE - Internal failure Vehicle Speed Warning Chime Problem Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 350 Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSE - Incorrect country code programmed in instrument cluster - Instrument cluster Driver Door Does Not Trip VTSS Test 1 - 3 SYMPTOM DRIVER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSE - Driver door ajar circuit Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 351 - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Headlamps Fail to Flash When Alarm Is Tripped Test 1 SYMPTOM HEADLAMPS FAIL TO FLASH WHEN ALARM IS TRIPPED POSSIBLE CAUSE - FCM DTCs or exterior lamp operation - Instrument cluster Horn Fails to Sound When Alarm Is Tripped Test 1 - 2 SYMPTOM HORN FAILS TO SOUND WHEN ALARM IS TRIPPED POSSIBLE CAUSE - DTC present - Horn circuit - Instrument cluster - VTSS Left Rear Door Does Not Trip VTSS (4 Door) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 352 Test 1 - 3 SYMPTOM LEFT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSE - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Passenger Door Does Not Trip VTSS Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 353 Test 1 - 3 SYMPTOM PASSENGER DOOR DOES NOT TRIP VTSS POSSIBLE CAUSE - Passenger door ajar circuit - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster Right Rear Door Does Not Trip VTSS (4 Door) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 354 Test 1 - 3 SYMPTOM RIGHT REAR DOOR DOES NOT TRIP VTSS (4 DOOR) POSSIBLE CAUSE - Passenger door ajar circuit malfunction - Verify VTSS operation - VTSS not enabled in FCM - Instrument cluster VTSS Will Not Arm Properly Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 355 Test 1 - 3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 356 Test 4 - 8 SYMPTOM VTSS WILL NOT ARM PROPERLY POSSIBLE CAUSE - VTSS not enabled - Check for DTCs and VTSS arming inhibitors - Check for SKIM no response - Cylinder lock switch ground open - Instrument cluster - Cylinder lock switch mux circuit open - Cylinder lock switch open - Instrument cluster - cylinder lock switch mux open Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 357 Body Control 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. Glossary of Terms ABS Antilock Brake System ACM Airbag Control Module ACT Actuator AECM Airbag Electronic Control Module (ACM) ASDM Airbag System Diagnostic Module (ACM) BCM Body Control Module BTSI Brake Transmission Shift Interlock CAB Controller Antilock Brake CMTC Compass/Mini-Trip Computer CPA Connector Positive Assurance DAB Driver Airbag DLC Data Link Connector DTC Diagnostic Trouble Code EBL Electric Back Lite (Rear Window Defogger) ECM Engine Control Module EVIC Electronic Vehicle Information Center FCM Front Control Module HVAC Heater Ventilation, Air Conditioning IC Instrument Cluster (MIC) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 358 IPM Integrated Power Module JB Junction Block MIC Mechanical Instrument Cluster NGC Next Generation Controller ODO Odometer ORC Occupant Restraint Controller PAB Passenger Airbag PCI Programmable Communication Interface (Vehicle Communication Bus) PCM Powertrain Control Module PDC Power Distribution Center PWM Pulse Width Modulated RKE Remote Keyless Entry RX Receive SRS Seat Belt Switch SBT Seat Belt Tensioner SIACM Side Impact Airbag Control Module SKIM Sentry Key Immobilizer Module SKIS Sentry Key Immobilizer System SRS Supplemental Restraint System SUV Sport Utility Vehicle TCCM Transfer Case Control Module TCM Transmission Control Module Transmit UGDO Universal Garage Door Opener VFD Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 359 Body Control Module: Scan Tool Testing and Procedures DRB III Error Messages and Blank Screen 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 360 SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: EXCEEDING THE LIMITS OF THE DRBIII MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRBIII if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table. - Voltage between any terminal and ground must not exceed 500 V DC or 500 C peak AC. - Use caution when measuring voltage above 25 V DC or 25 V AC. - Use the low current shunt to measure circuits up to 10 A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 361 Body Control Module: Service and Repair FRONT CONTROL MODULE REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the integrated power module from the engine compartment . 3. Remove the front control module retaining screws. 4. Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle. INSTALLATION 1. Install the front control module on the integrated power module assembly by pushing the 49-way electrical connector straight in. 2. Install the front control module retaining screws. Torque the screws to 7 in. lbs. 3. Install the integrated power module. 4. Connect the positive and negative battery cables. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 362 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Engine Control - PCM Initialization Procedure Powertrain Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Engine Control - PCM Initialization Procedure > Page 367 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Engine Control - PCM Initialization Procedure > Page 368 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Engine Control - PCM Initialization Procedure > Page 369 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Engine Control - PCM Initialization Procedure > Page 370 Powertrain Control Module: Technical Service Bulletins Engine Controls - Incorrect VIN Affects PCM Programming NUMBER: 18-024-02 GROUP: Vehicle Performance DATE: Aug. 12, 2002 SUBJECT: Incorrect Dual Wheel Identification in VIN, May Effect Replacement Powertrain Control Module Programming MODELS: 2003 (DR) Ram Truck DISCUSSION: The sixth character in the VIN is used to identify the vehicle series (1500, 2500, 3500). Some 2003 vehicles equipped with dual rear wheels, built prior to July 15, 2003 (MDH 0715XX), may have an incorrect number as the sixth character of the VIN. All vehicles equipped with dual wheels, sales code WLA, should have the number "4" as the sixth character. This identifies the vehicle as a 3500 series equipped with dual rear wheels. The incorrectly built vehicles will have the number "3" in that position. In the event that a Powertrain Control Module (PCM) would require replacement, the new module requires that the complete VIN be input during the programming procedure. It is important to remember that all vehicles equipped with dual rear wheels must have a "4" as the sixth character in the VIN. If a new PCM is programmed with a "3" as the sixth character and it is equipped with dual rear wheels a conflict is likely to occur with the ABS module which will set an error code. Dual rear wheel equipped vehicles require an ABS module calibrated for dual rear wheels. If PCM replacement is ever required, simply input a "4" instead of the "3" as the sixth character in the VIN when programming the PCM. This condition does not effect the Flash reprogramming procedure, which does not require input of the VIN. POLICY: Information Only Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 371 Powertrain Control Module: Specifications Powertrain Control Module Mounting Bolts ............................................................................................................................................. 4 Nm (35 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 372 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Connector Views Powertrain Control Module: Connector Views Powertrain Control Module C1 (JTEC) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Connector Views > Page 375 Powertrain Control Module C2 (JTEC) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Connector Views > Page 376 Powertrain Control Module C3 (JTEC) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description Powertrain Control Module: Description and Operation Description Fig.5 Powertrain Control Module (PCM) Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors The PCM operates the fuel system on vehicles equipped with gas engines. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description > Page 379 - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/ crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal PCM Outputs - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission converter clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description > Page 380 Powertrain Control Module: Description and Operation Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (Key-On) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-Up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Engine Warm-Up Mode This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description > Page 381 - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal - auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning for additional information. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning for additional information. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description > Page 382 requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/Neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. Ignition Switch Off Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Primary 5 volt supply: supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5 volt supply: supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power-train Control Module (PCM). The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Description > Page 383 Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 384 Powertrain Control Module: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING THE PCM POWER AND GROUNDS POSSIBLE CAUSES - (A14) PCM fused B+ circuit - (Y135) PCM fused ignition switch output circuit - (Z81) (Z82) PCM ground circuits Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Service and Repair > Powertrain Control Module Replacement Powertrain Control Module: Service and Repair Powertrain Control Module Replacement USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL Fig.6 PCM Location The PCM is located in the engine compartment attached to the dash panel. To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Service and Repair > Powertrain Control Module Replacement > Page 387 Fig.7 PCM Removal/Installation 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM and remove PCM from vehicle. INSTALLATION 1. Install PCM and 3 mounting bolts to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. Use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Service and Repair > Powertrain Control Module Replacement > Page 388 Powertrain Control Module: Service and Repair Programming the Powertrain Control Module (SBEC) The Sentry Key Immobilizer System (SKIS) Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the DRBIII® scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the DRBIII scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The DRBIII scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the DRB III scan tool. If NO is selected, the DRBIII scan tool will read, Enter odometer Reading. Enter the odometer reading from the instrument cluster and press ENTER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Integrated Power Module Auto Shut Down Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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: Description and Operation AUTOMATIC SHUT DOWN RELAY PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 393 Auto Shut Down (ASD) Relay: Testing and Inspection DIAGNOSIS AND TESTING - ASD RELAY Fig.3 Type 1 Relay (ISO Micro Relay) Fig.4 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - 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. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 394 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to 8, Wiring Diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 395 Auto Shut Down (ASD) Relay: Service and Repair ASD RELAY Fig.5 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Integrated Power Module (Front View) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Downstream Relay (California) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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: Description and Operation Oxygen Sensor Heater relay 5.9/8.0L If 4 oxygen sensors are used, a separate heater relay is used to supply voltage to the sensors heating elements for only the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through a Pulse Width Module (PWM) method. See: Relays and Modules - Power and Ground Distribution/Relay BoxApplications and ID. Pulse Width Module (PWM) - 5.9L/8.OL: Voltage to the 02 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through two separate Pulse Width Module (PWM) low side drivers. PWM is used on both the upstream and downstream 02 sensors if equipped with a Federal Emissions Package, and only on the 2 upstream sensors (1/1 and 2/1) if equipped with a California Emissions Package. The main objective for a PWM driver is to avoid overheating of the 02 sensor heater element. With exhaust temperatures increasing with time and engine speed, it's not required to have a full-voltage duty-cycle on the 02 heater elements. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 409 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 410 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 411 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 413 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 414 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 415 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 416 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 417 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 418 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 419 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 420 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 422 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 428 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 430 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 431 Fuel Pump Relay: Testing and Inspection DIAGNOSIS AND TESTING - FUEL PUMP RELAY Fig.3 Type 1 Relay (ISO Micro Relay) Fig.4 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - 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. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 432 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to 8, Wiring Diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 433 Fuel Pump Relay: Service and Repair FUEL PUMP RELAY Fig.5 PDC Location The Fuel Pump 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Integrated Power Module Auto Shut Down Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 437 Auto Shut Down (ASD) Relay: Description and Operation AUTOMATIC SHUT DOWN RELAY PCM OUTPUT The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 438 Auto Shut Down (ASD) Relay: Testing and Inspection DIAGNOSIS AND TESTING - ASD RELAY Fig.3 Type 1 Relay (ISO Micro Relay) Fig.4 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used. - 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. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 439 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to 8, Wiring Diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 440 Auto Shut Down (ASD) Relay: Service and Repair ASD RELAY Fig.5 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation IGNITION CONTROL The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. This engine uses a separate ignition coil for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 6 spark plugs. A separate electrical connector is used for each coil. Because of coil design, spark plug cables (secondary cables) are not used. A distributor is not used with this engine. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The Auto Shutdown (ASD) relay provides battery voltage to each ignition coil. The ignition system consists of: 6 Spark Plugs - 6 Separate Ignition Coils - 2 Knock Sensors - Powertrain Control Module (PCM) Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock sensors and MAP Sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 450 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 451 Air Bag Control Module: Connector Locations Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 452 Fig.38 Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 453 Fig.44 Standard Cab Left Side Body Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 454 Fig.45 Quad Cab Left Side Body Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 455 Air Bag Control Module: Diagrams Airbag Control Module Airbag Control Module Left Side Impact Airbag Control Module Right Side Impact Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 458 Air Bag Control Module: Vehicle Damage Warnings WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) Air Bag Control Module: Description and Operation Airbag Control Module (ACM) WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. - BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. - THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT Fig. 7 Airbag Control Module AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is secured with four screws to the top mounting surface of a stamped steel bracket welded onto the top of the floor panel transmission tunnel forward of the instrument panel center support bracket and below the instrument panel center stack in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. The ACM housing has integral mounting flanges on each side. Two of the mounting flanges, one on each side, have an integral locating pin on their lower surface. The left flanges have round mounting holes, while the flanges on the right side have slotted mounting holes. An arrow cast into the top of the ACM housing near the rear provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. A molded plastic electrical connector receptacle containing twenty-three terminal pins exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the front supplemental restraint system logic circuits and controls all of the front supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 461 The ACM microprocessor continuously monitors all of the front supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault or in some cases the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors inputs from the passenger airbag on/off switch. On models equipped with optional side curtain airbags, the ACM communicates with both the left and right Side Impact Airbag Control Modules (SIACM) over the PCI data bus. The SIACM notifies the ACM when it has detected a monitored system fault and stored a DTC in memory for its respective side curtain airbag system, and the ACM sets a DTC and controls the airbag indicator operation accordingly. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel support structure. These connections allow the ACM to be operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the front supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus network, and the electronic message inputs to and outputs from the ACM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 462 Air Bag Control Module: Description and Operation Side Impact Airbag Control Module (SIACM) WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT Fig. 53 Side Impact Airbag Control Module SIDE IMPACT AIRBAG CONTROL MODULE Supplemental driver and front passenger curtain airbags provide side impact protection for the front and rear seat occupants. Each curtain airbag has its own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just below the seat belt retractor. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. The results of the system test are transmitted on the PCI Bus to the ACM once each second. If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. On vehicles equipped with the optional side curtain airbags, a Side Impact Airbag Control Module (SIACM) and its mounting bracket are secured with four screws to the inside of each B-pillar behind (standard cab) or above (quad cab) the front outboard seat belt retractor, and concealed behind the B-pillar trim. Concealed within a hollow in the center of the die cast aluminum SIACM housing is the electronic circuitry of the SIACM which includes a microprocessor and an electronic impact sensor. The SIACM housing is secured to a die cast (standard cab) or stamped steel (quad cab) mounting bracket, which is unique for the right or left side application of this component. The SIACM should never be removed from its mounting bracket. The housing also receives a case ground through this mounting bracket when it is secured to the vehicle. A molded plastic electrical connector receptacle that exits the top of the SIACM housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Both the SIACM housing and its electrical connection are sealed to protect the internal electronic circuitry and components against moisture intrusion. The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 463 The microprocessor in the Side Impact Airbag Control Module (SIACM) contains the side curtain airbag system logic circuits and controls all of the features of only the side curtain airbag mounted on the same side of the vehicle as the SIACM. The SIACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used by the SIACM to communicate with the Airbag Control Module (ACM) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM communicates with both the left and right SIACM over the PCI data bus. The SIACM microprocessor continuously monitors all of the side curtain airbag electrical circuits to determine the system readiness. If the SIACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the ACM over the PCI data bus. The ACM will respond by sending an electronic message to the EMIC to turn on the airbag indicator, and by storing a DTC that will indicate whether the left or the right SIACM has stored the DTC that initiated the airbag indicator illumination. An active fault only remains for the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the SIACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the SIACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The SIACM receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Integrated Power Module (IPM). The SIACM has a case ground through its mounting bracket and also receives a power ground through a ground circuit and take out of the body wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the body sheet metal. These connections allow the SIACM to be operational whenever the ignition switch is in the Start or On positions. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. The hard wired inputs and outputs for the SIACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SIACM, the PCI data bus network, or the electronic message inputs to and outputs from the SIACM. The most reliable, efficient, and accurate means to diagnose the SIACM, the PCI data bus network, and the electronic message inputs to and outputs from the SIACM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover Air Bag Control Module: Service and Repair ACM Cover REMOVAL The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. Fig. 6 ACM Cover Remove/Install 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover away from the instrument panel far enough to disengage the two snap clip retainers from the instrument panel receptacles. 3. Remove the ACM cover from the instrument panel. INSTALLATION The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be reinstalled following ACM service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the ACM cover to the instrument panel. 2. Align the two snap clip retainers on the ACM cover with the receptacle on each side of the instrument panel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 466 Air Bag Control Module: Service and Repair Airbag Control Module REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. (Refer to RESTRAINTS/ACM COVER REMOVAL). Fig. 8 Airbag Control Module Remove/Install 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the instrument panel wire harness connector for the Airbag Control Module (ACM) from the connector receptacle located on the rearward facing side of the module. To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. From the right side of the floor panel transmission tunnel, loosen each of the two screws that secure the right side of the ACM to the bracket on the floor panel transmission tunnel about 7 millimeters (0.25 inch). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 467 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pins on the bottom of the ACM mounting flanges from the locating holes in the bracket, then slide the ACM toward the left far enough to disengage the slotted holes in the right ACM mounting flanges from under the heads of the two previously loosened right mounting screws. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) to the left side of the floor panel transmission tunnel near the ACM bracket. When the ACM is correctly positioned, the arrow on the ACM housing will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted holes in the right ACM mounting flanges under the heads of the two previously loosened right mounting screws, then engage the locating pins on the bottom of the ACM mounting flanges into the locating holes in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 14 Nm (10 ft. lbs.). 4. From the right side of the floor panel transmission tunnel, tighten each of the two screws that secure the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screws to 14 Nm (10 ft. lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the instrument panel wire harness connector for the ACM to the connector receptacle located on the rearward facing side of the module. Be certain that the latch and the red Connector Position Assurance (CPA) lock on the connector are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. (Refer to RESTRAINTS/ACM COVER INSTALLATION). 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 468 Air Bag Control Module: Service and Repair Side Impact Airbag Control Module REMOVAL Std CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Adjust the front seat to its most forward position for easiest access to the lower B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before hirther service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - REMOVAL - STANDARD CAB). Fig. 54 Side Impact Airbag Control Module Remove/Install - Std Cab 4. Remove the four screws that secure the Side Impact Airbag Control Module (SIACM) mounting bracket to the inside of the B-pillar. 5. Reach through the retractor mounting hole in the inner B-pillar to access and disengage the two plastic push-in fasteners that secure the SIACM to the inside of the B-pillar. 6. Pull the SIACM and mounting bracket out through the retractor mounting hole far enough to access and disconnect the body wire harness connector for the SIACM from the module connector receptacle. 7. Remove the SIACM and its mounting bracket from the B-pillar as a unit. Quad CAB WARNING Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 469 - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Adjust the front seat to its most forward position for easiest access to the lower B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before hirther service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - REMOVAL - QUAD CAB). Fig. 55 Side Impact Airbag Control Module Remove/Install - Quad Cab 4. Remove the four screws that secure the Side Impact Airbag Control Module (SIACM) mounting bracket to the inside of the B-pillar. 5. Reach through the retractor mounting hole in the inner B-pillar to access the SIACM and lift it upward far enough to disengage the hook on the mounting bracket from the slot on the inner B-pillar. 6. Pull the SIACM and mounting bracket out through the retractor mounting hole far enough to access and disconnect the body wire harness connector for the SIACM from the module connector receptacle. 7. Remove the SIACM and its mounting bracket from the B-pillar as a unit. INSTALLATION Std CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 470 SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Side Impact Airbag Control Module (SIACM) and its mounting bracket to the B-pillar as a unit. 2. Reconnect the body wire harness connector for the SIACM to the module connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the two plastic push-in fasteners that secure the SIACM to the inside of the B-pillar. 4. Loosely install the four screws that secure the SIACM mounting bracket to the base of the B-pillar. 5. Tighten the four screws that secure the SIACM mounting bracket to the B-pillar in the following sequence: upper left, lower right, lower left, upper right. Tighten the screws to 12 Nm (105 in. lbs.). 6. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - INSTALLATION - STANDARD CAB). 7. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Quad CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Side Impact Airbag Control Module (SIACM) and its mounting bracket to the B-pillar as a unit. 2. Reconnect the body wire harness connector for the SIACM to the module connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the hook on the SIACM mounting bracket in the slot of the inner B-pillar. 4. Loosely install the four screws that secure the SIACM mounting bracket to the inner B-pillar. 5. Tighten the four screws that secure the SIACM mounting bracket to the B-pillar in the following sequence: upper left, lower right, lower left, upper right. Tighten the screws to 12 Nm (105 in. lbs.). 6. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - INSTALLATION - QUAD CAB). 7. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Integrated Power Module Starter Motor Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 475 Starter Relay: Description and Operation STARTER MOTOR RELAY The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 476 Starter Relay: Testing and Inspection Fig. 12 Type 1 Relay DIAGNOSIS AND TESTING - STARTER MOTOR RELAY The starter relay (Fig. 12) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. Starter Relay Test 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and Clutch Pedal Position Switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear-shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to Park/Neutral position switch is OK, refer to Park/Neutral Position Switch. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 477 Starter Relay: Service and Repair Fig. 13 PDC Location REMOVAL The starter relay is located in the Power Distribution Center (PDC) (Fig. 13). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 483 Control Module: Diagrams Transmission Control Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 484 Transmission Control Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 485 Control Module: Description and Operation Fig.10 PCM/TCM Location TRANSMISSION CONTROL MODULE The Transmission Control Module (TCM) may be sub-module within the Powertrain Control Module (PCM) or a standalone module, depending on the vehicle engine. The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - DRBIII Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: Transmission Temperature (to PCM) - PRNDL Position (to BCM) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 486 In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRBIII scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.11 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRBIII Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 487 Clutch Volumes Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 488 expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 489 Control Module: Testing and Inspection ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) The pinion factor must be set when replacing the TCM. Note: The pinion factor is a fixed number and cannot be changed or updated in some vehicle applications. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Drive Learn Control Module: Service and Repair Drive Learn STANDARD PROCEDURE - DRIVE LEARN When a transmission is repaired and a Quick Learn procedure has been performed on the Transmission Control Module (TCM), the following Drive Learn procedure can be performed to fine tune any shifts which are particularly objectionable. NOTE: It is not necessary to perform the complete Drive Learn procedure every time the TCM is Quick Learned. Perform only the portions which target the objectionable shift. 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-D UD CVI. 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 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3. Repeat Step 1 and Step 2 until the recorded 1st N-D 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. 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 Norm N-D UD CVI. NOTE: The transmission oil temperature must be between 80 - 110 °F (27 - 43 °C) to learn the UD CVI. Additional learning occurs at temperatures as low as 0 °F and as high as 200°F. This procedure may be performed at any temperature that experiences poor shift quality. Although the UD CVI may not change, shift quality should improve. 1. Start the vehicle engine and shift to drive. 2. Move the vehicle forward to a speed of at least 16 km/h (10 mph) and come to a stop. This ensures no air is present in the UD hydraulic circuit. 3. Perform repeated N-D shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor Norm N-D 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-D shift then the normal value shown which is used for 4-3 coastdown and kickdowns. Perform repeated shifts in this temperature range until the Norm N-D UD CVI value stabilizes and the N-D shifts become smooth. 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 1st 2-3 OD CVI. 3. Repeat Step 1 and Step 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. Learn A Smooth 2-3 And 3-4 Upshift NOTE: The transmission oil temperature must be above 110 °F (43 °C). Use the following steps to have the TCM learn the OD and 4C CVI's. 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. Learn A Smooth 4-3 Coastdown And Part Throttle 4-3 Kickdown NOTE: The transmission oil temperature must be above 110 °F (43 °C). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Drive Learn > Page 492 Use the following steps to have the TCM learn the UD shift volume. 1. At a vehicle speed between 64-97 km/h (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. 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 48 km/h (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. Learn A Smooth Manual 2-1 Pulldown Shift As Well As A Neutral To Reverse Shift NOTE: The transmission oil temperature must be above 110 °F (43 °C). Use the following steps to have the TCM learn the LR volume. 1. With the vehicle speed around 40-48 km/h (25-30 MPH) in Manual 2nd, perform manual pull-downs to Low or 1st gear at closed throttle. 2. Repeat Step 1 until the LR CVI becomes stable and the manual 2-1 becomes smooth. Learn A Smooth Neutral To Reverse Shift 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. 2. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. Learn A Smooth 4-5 Upshift NOTE: The transmission oil temperature must be above 110 °F (43 °C). Use the following steps to have the TCM learn the Alt 2C CVI. 1. Accelerate the vehicle through 88 km/h (55mph) at a steady 10-15 degree throttle opening and perform multiple 4-5 upshifts. 2. Repeat Step 1 until the 4-5 shift become smooth and the Alt 2C CVI become stable. There is a separate 2C volume used and learned for 4-5 shifts, 2CA. It is independent of the 2C CVI learned on 3-2 kickdowns. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Drive Learn > Page 493 Control Module: Service and Repair TCM Quick Learn STANDARD PROCEDURE - TCM QUICK LEARN The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete - The calculated oil temperature must be above 60 °F and below 200 °F Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Integrated Power Module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 497 Transmission Control Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 501 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 502 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 503 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 506 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 507 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 508 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 509 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 510 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 511 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 512 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 513 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 514 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 518 Transmission Control System Relay: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 520 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 521 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 522 EATX - 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 525 Transmission Control System Relay: Description and Operation 45RFE 4 Speed TRANSMISSION CONTROL RELAY - 45RFE/545RFE Automatic Transmission DESCRIPTION NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 526 Transmission Control System Relay: Description and Operation 45RFE/545RFE Automatic Transmission RELAY-TRANSMISSION CONTROL DESCRIPTION 45RFE/545RFE Automatic Transmission The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation Heated Glass Element Relay: Description and Operation OPERATION The rear window defogger system is turned on by a momentary switch located in the A/C-heater control on the instillment panel. When the rear window defogger switch is pressed to the On position, current is directed through the rear window defogger relay to the rear defogger grid lines. The heated grid lines heat the rear glass to help clear the rear window surface of fog or frost. A yellow indicator above the switch will illuminate to indicate when the rear window defogger system is turned on. The A/C-heater control contains the rear window defogger system control circuitry. NOTE: The rear window defogger turns off automatically after approximately 10 minutes of initial operation. Each following activation cycle of the defogger system will last approximately ten minutes also. The rear window defogger system 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 pressed to the On position again during the same ignition cycle, the rear window defogger system will automatically turn off after about ten minutes also. The rear window defogger system will automatically shut off if the ignition switch is turned to the Off position, or it can be turned off manually by pressing the defogger switch a second time. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Description and Operation Rear Defogger Relay: Description and Operation OPERATION The rear window defogger system is turned on by a momentary switch located in the A/C-heater control on the instillment panel. When the rear window defogger switch is pressed to the On position, current is directed through the rear window defogger relay to the rear defogger grid lines. The heated grid lines heat the rear glass to help clear the rear window surface of fog or frost. A yellow indicator above the switch will illuminate to indicate when the rear window defogger system is turned on. The A/C-heater control contains the rear window defogger system control circuitry. NOTE: The rear window defogger turns off automatically after approximately 10 minutes of initial operation. Each following activation cycle of the defogger system will last approximately ten minutes also. The rear window defogger system 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 pressed to the On position again during the same ignition cycle, the rear window defogger system will automatically turn off after about ten minutes also. The rear window defogger system will automatically shut off if the ignition switch is turned to the Off position, or it can be turned off manually by pressing the defogger switch a second time. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation Fig.25 Wiper Module WIPER MODULE The wiper motor bracket is secured with two screws below the wiper motor through two rubber insulators to the bottom of the cowl plenum panel beneath the cowl plenum cover/grille panel. Two screws secure the top of the wiper module bracket to the cowl plenum panel through rubber insulators located on the outboard end of each pivot bracket. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member that has a die cast pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has two rubber insulated mounting ears at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 538 The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 539 Wiper Control Module: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel from over the cowl plenum. Fig.26 Wiper Module Remove/Install 5. Disconnect the left headlamp and dash wire harness connector for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. 7. Remove the two screws that secure the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION 1. Position the wiper module into the cowl plenum as a unit. 2. Install the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 7 Nm (60 in. lbs.). 3. Install and tighten the screws that secure the wiper module to the bottom of the cowl plenum panel. Tighten the screw on the passenger side, followed by the screw on the driver side. Tighten the screws to 7 Nm (60 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector for the wiper motor to the motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Component Locations Wiper Relay: Component Locations Integrated Power Module Wiper High/Low Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Component Locations > Page 544 Wiper On/Off Relay Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 545 Wiper Relay: Service Precautions Fig. 19 ISO Micro Relay The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low Wiper Relay: Description and Operation Relay-Wiper High/Low Fig.22 ISO Micro Relay WIPER HIGH/LOW RELAY The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the Integrated Power Module (IPM) through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the wiper high/low relay operation requires the use of a DRBIII scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low > Page 548 Wiper Relay: Description and Operation Relay-Wiper On/Off Fig.27 ISO Micro Relay WIPER ON/OFF RELAY The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a DRBIII scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Test Wiper Relay: Testing and Inspection Wiper High/Low Relay Test Fig.23 ISO Micro Relay DIAGNOSIS AND TESTING - WIPER HIGH/LOW RELAY The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the wiper high/low relay from the IPM. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRBIII scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Test > Page 551 Wiper Relay: Testing and Inspection Wiper On/Off Relay Test Fig.28 ISO Micro Relay DIAGNOSIS AND TESTING - WIPER ON/OFF RELAY The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the wiper on/off relay from the IPM. (Refer to ELECTRICAL/WIPERS/WASHERS/ WIPER ON/OFF RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRBIII scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Wiper High/Low Relay Replacement Wiper Relay: Service and Repair Wiper High/Low Relay Replacement WIPER HIGH/LOW RELAY REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.24 Integrated Power Module 2. Remove the cover from the Integrated Power Module (IPM). 3. Remove the wiper high/low relay by grasping it firmly and pulling it straight out from the receptacle in the IPM. INSTALLATION 1. Position the wiper high/low relay to the proper receptacle in the Integrated Power Module (IPM). 2. Align the wiper high/low relay terminals with the terminal cavities in the IPM receptacle. 3. Push firmly and evenly on the top of the wiper high/low relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 4. Reinstall the cover onto the IPM. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Wiper High/Low Relay Replacement > Page 554 Wiper Relay: Service and Repair Wiper on/Off Relay Replacement WIPER ON/OFF RELAY REMOVAL 1. Disconnect and isolate the battery negative cable. Fig.29 Integrated Power Module 2. Remove the cover from the Integrated Power Module (IPM). 3. Remove the wiper on/off relay by grasping it firmly and pulling it straight out from the receptacle in the IPM. INSTALLATION 1. Position the wiper on/off relay to the proper receptacle in the Integrated Power Module (IPM). 2. Align the wiper on/off relay terminals with the terminal cavities in the IPM receptacle. 3. Push firmly and evenly on the top of the wiper on/off relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 4. Reinstall the cover onto the IPM. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Component Locations > Page 561 Fig.42 Standard Cab Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Component Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Component Locations > Page 566 Pedal Positioning Switch: Connector Locations Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Component Locations > Page 567 Fig.39 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 568 Adjustable Pedal Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 569 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDAL SWITCH REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector from the adjustable pedal switch. 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector to the adjustable pedal switch. 3. Install the lower drivers side bezel. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Remote Radio Switch Left Remote Radio Switch Right Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 573 Remote Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 574 Remote Switch: Description and Operation Fig. 12 Remote Radio Switch Operational View A remote radio control switch option is available on some models. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a DRB III scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the features and control functions for each of the remote radio switches, refer to the owner's manual. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 575 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 13 Remote Radio Switches 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel (Refer to AUDIO/REMOTE SWITCHES - REMOVAL). Remote Radio Switch Test Table 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 4. If not OK, repair the open or shorted radio control mux circuit to the Integrated Power Module (IPM) as required. 4. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 576 and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 5. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 577 Remote Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the vehicle (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). 3. Remove the speed control switches (Refer to SPEED CONTROL/SWITCH - REMOVAL). 4. Unplug the wire harness connector from the remote radio switch(es). Fig. 14 Remote Switches 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install remote radio switch to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (Refer to SPEED CONTROL/SWITCH INSTALLATION). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation Road Temperature Sensor: Description and Operation AMBIENT TEMP SENSOR Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) J1850 data bus circuit. The FCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. Refer to Front Control Module in Electronic Control Modules. For complete circuit diagrams, refer to the appropriate wiring information. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the Front Control Module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Front Control Module. Based upon the resistance in the sensor, the Front Control Module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The Front Control Module then sends the proper ambient temperature messages to the EVIC, CMTC over the PCI J1850 data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Front Control Module, the Programmable Communications Interface (PCI) data bus, and a portion of the Electronics module. If any portion of the ambient temperature sensor circuit fails, the Front Control Module will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed by referring to Diagnosis and Testing - Ambient Temperature Sensor, and Diagnosis and Testing - Ambient Temperature Sensor Circuit. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing - Overhead Console in this group. For complete circuit diagrams, refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error Road Temperature Sensor: Testing and Inspection FCM-Ambient Temp Configuration Error Test 1 SYMPTOM FCM - AMBIENT TEMP CONFIGURATION ERROR WHEN MONITORED During power up. SET CONDITION The FCM detects that an Ambient Temperature Sensor is present on the input circuit and has gone through auto-configuration and another module is transmitting a redundant ambient temp message. POSSIBLE CAUSE - Incorrect configuration Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error > Page 583 Road Temperature Sensor: Testing and Inspection FCM-Ambient Temp Sensor Input Low Test 1 - 2 Test 3 SYMPTOM FCM - AMBIENT TEMP SENSOR INPUT LOW WHEN MONITORED Continuous with the ignition on. SET CONDITION The FCM detects less than 0.5 volts on the Ambient Temperature Sensor Signal circuit. POSSIBLE CAUSE - Ambient temperature sensor - Ambient temperature sensor signal circuit shorted to ground - Ambient temperature sensor signal circuit shorted to sensor return circuit - Front control module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error > Page 584 Road Temperature Sensor: Testing and Inspection FCM-Ambient Temp Sensor Input Open Test 1 - 2 Test 3 - 4 SYMPTOM FCM - AMBIENT TEMP SENSOR INPUT OPEN WHEN MONITORED Continuous with the ignition on. SET CONDITION The FCM detects more than 5.0 volts on the Ambient Temperature Sensor Signal circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error > Page 585 POSSIBLE CAUSE - Ambient temperature sensor signal circuit shorted to voltage - Ambient temperature sensor - Ambient temperature sensor return circuit open - Ambient temperature sensor signal circuit open - Front control module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error > Page 586 Road Temperature Sensor: Testing and Inspection Ambient Temperature Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilohms. At 55 °C (140 °F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Diagnosis and Testing - Ambient Temperature Sensor Circuit in this group. If not OK, replace the faulty ambient temperature sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > FCM-Ambient Temp Configuration Error > Page 587 Road Temperature Sensor: Testing and Inspection Ambient Temperature Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Front Control Module wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the Front Control Module wire harness connector. There should be continuity If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing - Overhead Console in this group. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > Page 588 Road Temperature Sensor: Service and Repair AMBIENT TEMPERATURE SENSOR REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Lock Cylinder Switch: Diagrams Cylinder Lock Switch - Driver (Premium) Cylinder Lock Switch - Passenger (Premium) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Component Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Component Locations > Page 597 Pedal Positioning Switch: Connector Locations Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Component Locations > Page 598 Fig.39 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 599 Adjustable Pedal Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 600 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDAL SWITCH REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector from the adjustable pedal switch. 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector to the adjustable pedal switch. 3. Install the lower drivers side bezel. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch Passenger Door Window/Lock Switch Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 604 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin- out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Fig.5 Powr Lock Switch Connector Receptable Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 605 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, gently pry the switch bezel from the door panel. 3. Disconnect the electrical harness connector from the switch. 4. Remove switch from bezel. INSTALLATION 1. Insert switch to bezel. 2. Connect electrical harness connector to switch. 3. Press bezel into place on door trim panel. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to POWER LOCKS/DOOR MODULE - DIAGNOSIS AND TESTING). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 609 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE - REMOVAL). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations LUMBAR CONTROL SWITCH The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 613 Power Seat Switch: Diagrams Passenger Lumbar Switch Power Seat Switch Driver Power Seat Switch Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 614 Power Seat Switch: Description and Operation Fig. 1 DR Power Seat Switch DRIVER SEAT SWITCH The power seat on this model can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch on this model has an additional switch knob for adjusting the power lumbar support. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or faulty, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 615 Fig. 1 DR Power Seat Switch PASSENGER SEAT SWITCH The power seat on this model can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch on this model has an additional switch knob for adjusting the power lumbar support. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or faulty the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. LUMBAR CONTROL SWITCH The power lumbar seat option includes an electrically operated lumbar support mechanism. A single two-way momentary power lumbar switch is integral with the power seat switches. The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. The switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. The power lumbar switches cannot be adjusted or repaired and, if faulty or damaged, the seat switch assembly must be replaced. When the power lumbar switch paddle is actuated, a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster motor. The motor operates to move the lumbar adjuster through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the motor to run in the opposite direction. The power lumbar switch should not be held applied in either direction after the adjuster has reached its travel limit. The power lumbar adjuster motor contains a self-resetting circuit breaker to protect it from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Switch Test Power Seat Switch: Testing and Inspection Driver Seat Switch Test For circuit descriptions and diagrams, refer to Wiring. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Fig. 2 Testing Driver Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, refer to Power Seat Track Diagnosis and Testing in this group. If not OK, replace the faulty power seat switch. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Switch Test > Page 618 Power Seat Switch: Testing and Inspection Passenger Seat Switch Test For circuit descriptions and diagrams, refer to Wiring. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Fig. 5 Testing Passenger Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, refer to Power Seat Track Diagnosis and Testing in this group. If not OK, replace the faulty power seat switch. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement Power Seat Switch: Service and Repair Driver Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to the Body section for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. Power Seat Switch Remove/Install - Typical 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and install the screws that secure the power seat switch to seat cushion side shield. 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. Refer to the Body section of the service manual for the procedure. 4. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement > Page 621 Power Seat Switch: Service and Repair Passenger Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to the Body section for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. Power Seat Switch Remove/Install - Typical 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and install the screws that secure the power seat switch to seat cushion side shield. 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. Refer to the Body section for the procedure. 4. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement > Page 622 Power Seat Switch: Service and Repair Lumbar Control Switch Replacement REMOVAL The power lumbar switch is integral with the other power seat switches. Refer to the appropriate driver or passenger power front seat switch removal and/or installation procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defective. The heated seat cushion element must be replaced if the temperature sensor is defective. The temperature sensor is a NTC thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 626 Seat Heater Sensor: Testing and Inspection NOTE: ANY RESISTANCE VALUES (OHMS) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. 1. Position the appropriate seat in the full forward position. 2. Make certain the ignition switch is in the OFF position. 3. Disconnect the 4-way heated seat wire harness connector from the seat cushion frame. Using an ohmmeter, check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity in the 4-way heated seat wire harness connector. The heated seat sensor resistance should be between 1 kilohm and 100 kilohms. If OK, go to Step 4. If not OK, replace the faulty seat cushion heating element assembly 4. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. For complete circuit diagrams, refer to Wiring Diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 627 Seat Heater Sensor: Service and Repair REMOVAL 1. For heated seat sensor replacement procedure (Refer to HEATED SEATS/HEATED SEAT ELEMENT - REMOVAL). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Fig.35 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 631 Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 632 Fig.38 Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 633 Seat Heater Switch: Diagrams Heated Seat Switch - Driver Heated Seat Switch - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 634 Seat Heater Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 635 Seat Heater Switch: Description and Operation DRIVER HEATED SEAT SWITCH The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The momentary, bi-directional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module on the mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are ON. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned ON, and their illumination intensity is controlled by the panel lamps dimmer switch. PASSENGER HEATED SEAT SWITCH The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The momentary, bi-directional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module on the mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard- wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater off. The heated seat module will then turn the heated seat elements for that seat off. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned ON, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test Seat Heater Switch: Testing and Inspection Driver Heated Seat Switch Test Refer to Wiring Diagrams for the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, refer to Instrument Cluster for the proper cluster illumination lamps diagnosis and testing procedures. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the instrument panel wire harness connector for the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps ON with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer switch signal circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, replace the faulty heated seat switch. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the Integrated Power Module fuse as required. Fig. 1 Heated Seat Switches 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. NOTE: ANY RESISTANCE VALUES (OHMS ) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 638 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 639 Seat Heater Switch: Testing and Inspection Passenger Heated Seat Switch Test Refer to Wiring Diagrams for the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, refer to Instrument Cluster for the proper cluster illumination lamps diagnosis and testing procedures. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the instrument panel wire harness connector for the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps ON with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer switch signal circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, replace the faulty heated seat switch. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the Integrated Power Module fuse as required. Fig. 8 Heated Seat Switches 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. NOTE: ANY RESISTANCE VALUES (OHMS ) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 640 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement Seat Heater Switch: Service and Repair Driver Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel. 3. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 4. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 5. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. Note that the driver side and passenger side switches are identical in appearance except for the keyway in the connector receptacle on the backs of the switches. The driver side switch has the keyway located near the bottom of the connector receptacle and should be installed in the left mounting hole of the heated seat switch bezel. The passenger side switch has the keyway located near the top of the connector receptacle and should be installed in the right mounting hole of the heated seat switch bezel. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement > Page 643 Seat Heater Switch: Service and Repair Passenger Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel. 3. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 4. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 5. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. Note that the driver side and passenger side switches are identical in appearance except for the keyway in the connector receptacle on the backs of the switches. The driver side switch has the keyway located near the bottom of the connector receptacle and should be installed in the left mounting hole of the heated seat switch bezel. The passenger side switch has the keyway located near the top of the connector receptacle and should be installed in the right mounting hole of the heated seat switch bezel. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 648 Brake Fluid Level Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 649 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH CIRCUIT The switch signals the CAB for a hydraulic fluid problem. The antilock system uses input from the brake fluid level switch when activated. A low brake fluid condition in the master cylinder will close the switch circuit and read 0 volts. When the brake fluid level is at specifications, the switch will open and circuit sense voltage will read 5 volts. This signal tells the CAB if there is enough brake fluid in the master cylinder to have an antilock operation. The brake fluid level switch is located in the master cylinder with 10k resistor. The switch is a Hall effect design and uses a float to determine level. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 653 Fig.28 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 654 Fig.31 Left Side Engine Compartment and Hood Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 658 Fig.27 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt ................................................................................................................................................ 21 Nm (190 in. lbs.) Wheel Speed Sensors Bracket To Knuckle ............................................................................................................................................. 6.7 Nm (60 in. lbs.) Wheel Speed Sensors Rear Sensor Stud ............................................................................................................................................. 22.5 Nm (200 in. lbs.) Rear Wheel Speed Sensor Mounting Bolt .............................................................................................................................................. 24 Nm (200 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Rear Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 664 Wheel Speed Sensor: Connector Locations Fig.25 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 665 Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 666 Fig.31 Left Side Engine Compartment and Hood Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 667 Fig.49 Rear Chassis Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Wheel Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 670 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 671 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 672 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 673 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 677 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 678 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 679 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 680 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 681 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 682 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 684 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Wheel Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 689 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 690 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 692 Wheel Speed Sensor: Connector Views Left Front Wheel Speed Sensor (ABS) Rear Wheel Speed Sensor (ABS) Right Front Wheel Speed Sensor (ABS) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Wheel Speed Sensor: Electrical Diagrams For wiring diagram for the rear wheel speed sensor please refer to: Diagrams, Electrical, Diagrams by number, Group 8W-34 (Rear Wheel Antilock Brakes), See: Diagrams/Electrical Diagrams/Diagrams By Number/Group 8W-34 (Rear Wheel Antilock Brakes) For wiring diagram for the all wheel speed sensor please refer to: Diagrams, Electrical, Diagrams by number, Group 8W-35 All Wheel Antilock Brakes, See: Diagrams/Electrical Diagrams/Diagrams By Number/Group 8W-35 (All Wheel Antilock Brakes) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 694 Wheel Speed Sensor: Description and Operation WHEEL SPEED SENSORS The EBC 125 (RWAL) system uses only one speed sensor mounted in the rear axle for the rear wheels. The EBC 325 (ABS) system uses one wheel speed sensor on each front wheel, and one mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: ^ A magnetic/coil pick-up (speed sensor) that is mounted to a fixed component ^ An air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the CAB takes control for antilock action through the HCU. Diagnostically, the coils of the wheel speed sensors have different amounts of resistance based upon the location. When measured across the connector two terminals, the resistance should be: Front sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2259 - 2761 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1800 - 2200 Ohms -40 °C (-40 °F) ........................................................................................................................................... .................................... 1332 - 1628 Ohms Rear sensor: 90 °C (194 °F) ..................................................................................................................................... ........................................... 2900 - 3600 Ohms 25 °C (77 °F) ............................................................. ..................................................................................................................... 1600 - 2300 Ohms -40 °C (-40 °F) ........................................................................................................................................... ..................................... 1000 - 1400 Ohms NOTE:For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold. On a EBC 325 (ABS) system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On the EBC 125 (RWAL) and EBC 325 (ABS) systems the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the amber ABS warning indicator circuit via the PCI BUS, and store diagnostic trouble codes if it detects a problem with any or all of the wheel speed sensors: ^ Incorrect circuit resistance when checked with no vehicle movement ^ Incorrect sensor output during vehicle movement ^ Erratic sensor output during vehicle movement DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 695 When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal ^ Number of windings in the sensor; more windings provide a stronger signal ^ Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be ^ Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 inch. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 696 driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 697 Wheel Speed Sensor: Testing and Inspection DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions, which are mechanical in nature, should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or ORB 111 scan tool is used to diagnose the Antilock Brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt from the hub. 3. Remove the wheel speed sensor from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor to the hub. 3. Install the wheel speed sensor mounting bolt to the hub. Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 700 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud from the sensor and shield. 4. Remove the sensor and shield from the differential housing. 5. Disconnect the sensor wire harness and remove the sensor. INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor in the differential housing. 4. Install the sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or 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 - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Description and Operation > Page 709 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair ENGINE COOLANT TEMPERATURE SENSOR - 3.7L V-6 REMOVAL The Engine Coolant Temperature (ECT) sensor on the 3.7L engine is installed into a water jacket at front of intake manifold near rear of generator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor from the intake manifold. INSTALLATION 1. Apply thread sealant to sensor threads. 2. Install sensor to engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Speed Control Switch Mounting Screws 1.7 Nm 15 In. Lbs Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 714 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 715 Cruise Control Switch: Diagrams Speed Control Switch - Left (ETC) Speed Control Switch - Left (Except ETC) Speed Control Switch - Right (ETC) Speed Control Switch - Right (Except ETC) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 716 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE(S) FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 717 Cruise Control Switch: Description and Operation SPEED CONTROL SWITCHES Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) 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. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) 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 (ECM for diesel). 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 (ECM for diesel) 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 718 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. Fig.10 Speed Control Switches (Except 5.7L V-8 Engine) Fig.11 Speed Control Switches (With 5, Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 719 1. Remove switch mounting screw. 2. Pull switch from steering wheel. 3. Unplug electrical connector from switch or, switch pigtail wire harness from steering wheel wire harness and remove switch. INSTALLATION 1. Plug electrical connector into switch or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 726 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 727 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 728 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 729 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 737 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 738 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 740 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Oil Pressure Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 745 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 746 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Engine Oil Pressure Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 749 Oil Pressure Sensor: Service and Repair OIL PRESSURE SENSOR/SWITCH REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 71). 5. Remove the pressure sender (Fig. 71). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Fig.31 Left Side Engine Compartment and Hood Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 756 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 757 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 758 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 759 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 760 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 761 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 762 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 763 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 764 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 765 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 766 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 767 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 768 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 770 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Ambient Temperature Sensor / Switch HVAC: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 776 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 779 8w-49-3 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 780 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the Front Control Module (FCM) and displayed by the Compass/mini-trip Computer /Electronic Vehicle Information Center (CMTC/EVIC). The FCM receives a hardwire input from the Ambient Temperature Sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the Programmable Communication Interface (Vehicle Communication Bus) (PCI) Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the CMTC/EVIC display indicates 54° C (130° F) or the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate a SHORT circuit condition. If the CMTC/EVIC display indicates -40° C (-40 ° F) or the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the Sensor Test. Test the ATS circuits using the diagnostics at Body Control System. If the EVIC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the EVIC temperature display is inoperative or incorrect, replace the FCM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Test Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor Test AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Test > Page 783 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection FCM-Ambient Temp Configuration Error Test 1 SYMPTOM FCM - AMBIENT TEMP CONFIGURATION ERROR WHEN MONITORED During power up. SET CONDITION The FCM detects that an Ambient Temperature Sensor is present on the input circuit and has gone through auto-configuration and another module is transmitting a redundant ambient temp message. POSSIBLE CAUSE - Incorrect configuration Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Test > Page 784 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection FCM-Ambient Temp Sensor Input Low Test 1 - 2 Test 3 SYMPTOM FCM - AMBIENT TEMP SENSOR INPUT LOW WHEN MONITORED Continuous with the ignition on. SET CONDITION The FCM detects less than 0.5 volts on the Ambient Temperature Sensor Signal circuit. POSSIBLE CAUSE - Ambient temperature sensor - Ambient temperature sensor signal circuit shorted to ground - Ambient temperature sensor signal circuit shorted to sensor return circuit - Front control module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Test > Page 785 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection FCM-Ambient Temp Sensor Input Open Test 1 - 2 Test 3 - 4 SYMPTOM FCM - AMBIENT TEMP SENSOR INPUT OPEN WHEN MONITORED Continuous with the ignition on. SET CONDITION The FCM detects more than 5.0 volts on the Ambient Temperature Sensor Signal circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Test > Page 786 POSSIBLE CAUSE - Ambient temperature sensor signal circuit shorted to voltage - Ambient temperature sensor - Ambient temperature sensor return circuit open - Ambient temperature sensor signal circuit open - Front control module Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 790 Blower Motor Switch: Description and Operation The A/C Heater blower motor is controlled by a four position rotary-type blower motor switch, mounted in the A/C Heater control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position on the blower motor switch. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 791 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC) fuse Batt A-2. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the A/C Heater control from the instrument panel. Check for continuity between the ground circuit cavity of the A/C Heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the A/C Heater control wire harness connector unplugged, place the A/C Heater mode control switch knob in any position except the OFF position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the A/C Heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the A/C Heater control connector and the blower motor resistor as required. If not OK, replace the faulty A/C Heater control unit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 792 Blower Motor Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. The blower motor switch cannot be repaired and, if faulty or damaged the entire A/C heater control unit must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 796 Evaporator Temperature Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condensor in the front corner of the engine compartment. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 800 A/C Pressure Transducer Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 801 Refrigerant Pressure Sensor / Switch: Description and Operation A/C PRESSURE TRANSDUCER The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condensor in the front corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the liquid line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a take out and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it musty be replaced. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10 °C due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 802 Refrigerant Pressure Sensor / Switch: Testing and Inspection A/C PRESSURE TRANSDUCER A/C Pressure Transducer Voltage The A/C pressure transducer is tested using a DRB III scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage table for the possible condition indicated by the transducer voltage readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 803 Refrigerant Pressure Sensor / Switch: Service and Repair A/C PRESSURE TRANSDUCER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector for the A/C pressure transducer from the transducer connector receptacle. 3. Using an open end wrench, unscrew the A/C pressure transducer from the fitting on the discharge line between the compressor and the condenser. 4. Remove the seal from the A/C pressure transducer fitting and discard. INSTALLATION 1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. 2. Using an open end wrench, install and tighten the A/C pressure transducer onto the fitting on the discharge line between the compressor and the condenser. 3. Reconnect the wire harness connector for the A/C pressure transducer to the transducer connector receptacle. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Fig.42 Standard Cab Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 808 Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 812 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 813 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 814 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 815 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 816 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 818 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 819 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 820 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 821 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 822 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 823 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 825 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 831 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Door Switch: Connector Views Door Ajar Switch Driver (Base) Door Ajar Switch Left Rear (Base) Door Ajar Switch Passenger (Base) Door Ajar Switch Right Rear (Base) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 834 Door Switch: Electrical Diagrams The Instrument Panel Gauges and Warning Indicators are not controlled by individual circuits. The ElectroMechanical Instrument Cluster (EMIC) assembly is driven by the BCM via the Programmable Communications Interface (PCI) data bus. For additional information on how the system operates, See: Instrument Panel, Gauges and Warning Indicators/Description and Operation For diagnosis of the EMIC/MIC, See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Door Ajar System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 835 Door Switch: Description and Operation The Instrument Panel Gauges and Warning Indicators are not controlled by individual circuits. The ElectroMechanical Instrument Cluster (EMIC) assembly is driven by the BCM via the Programmable Communications Interface (PCI) data bus. For additional information on how the system operates, See: Instrument Panel, Gauges and Warning Indicators/Description and Operation For diagnosis of the EMIC/MIC, See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Instrument Cluster when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Refer to the Body section under Doors for the removal and installation procedure. The door ajar switches close a path to ground for the Instrument Cluster when a door is opened. The passenger front door is connected in a parallel-series circuit between ground and the Instrument Cluster, while the driver side front door ajar switch is connected in series between ground and the Instrument Cluster to provide a unique input. The Instrument Cluster reads the switch status, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Fig. 4 Location - Fuel Gauge Sending Unit The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (Fig. 4). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 842 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 843 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 844 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 848 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 849 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 850 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 851 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 852 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 853 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 855 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 861 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 863 Fuel Gauge Sender: Description and Operation Fuel Level Sending Unit / Sensor The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12 V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 864 Fuel Gauge Sender: Testing and Inspection FUEL LEVEL SENDING UNIT The fuel level sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is a part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms (± 6 ohms). With float in down position, resistance should be 220 ohms (± 6 ohms). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 865 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENDING UNIT/SENSOR REMOVAL Fig.3 Location - Fuel Gauge Sending Unit The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (Fig. 3). 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. Fig.4 Fuel Gauge Sending Unit - R/I 2. To remove sending unit from pump module, lift on plastic locking tab (Fig. 4) while sliding sending unit tracks. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 866 3. Disconnect 4-wire electrical connector (Fig. 3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY IN IGNITION SWITCH The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation > Page 870 Key Reminder Switch: Testing and Inspection DIAGNOSIS, TESTING AND REPAIR - IGNITION SWITCH If the key removal effort is excessive on a vehicle with a automatic transmission first adjust the shift linkage. If the ignition switch effort is excessive remove the ignition key cylinder from the steering column. Check the turning effort of the key cylinder. If the ignition key cylinder effort is excessive replace the key cylinder. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 874 Fig.27 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 882 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 883 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 884 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 888 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 889 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 890 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 891 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 892 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 893 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 895 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 901 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Backup Lamp Switch (3.7/4.7/5.7/8.0L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 904 Backup Lamp Switch: Description and Operation Fig.1 Backup Lamp Switch - Typical Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type back-up lamp switch. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The backup lamp switch has a threaded body and a hex formation near the plunger end of the switch, and an integral connector at the opposite end of the switch. When installed, only the connector and the hex formation are visible on the outside of the transmission housing. Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the back-up lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. A take out of the engine wire harness connects the backup lamp switch to the vehicle electrical system. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 905 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Brake Light Switch: Component Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 910 Brake Light Switch: Connector Locations Fig.32 Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 911 Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 912 Fig.39 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 913 Brake Lamp Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 914 Brake Light Switch: Description and Operation BRAKE LAMP SWITCH The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is hard wired to the Center High Mount Stop Lamp (CHMSL) and also monitored by the Instrument Cluster for use by the brake lamp, speed control brake sensor circuits and electronic brake distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the brake lamp switch transitions, the CHMSL transitions and instrument cluster transmits a brake applied/released message on the bus. The Integrated Power Module (IPM) will then transition the brake lamps. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Vehicles equipped with the speed control option use a dual function brake lamp switch The PCM monitors the state of the dual function brake lamp switch The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged) The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low The low voltage signal, monitored by the PCM, indicates that the brakes are not applied When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on Through the brake switch, voltage is routed to the speed control servo solenoids The speed control solenoids (vacuum, vent and dump) are provided this voltage any time the speed control is ON and the brakes are disengaged When the driver applies the brakes, the contacts open and voltage is interrupted to the solenoids The normally open contacts are fed battery voltage When the brakes are applied, battery voltage is supplied to the brake lamps The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed, a new switch must be installed and adjusted. BRAKE LAMP SWITCH CIRCUIT This switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake pedal switch when activated. A released brake pedal will close the switch circuit and read 0 volts. When the driver applies the brake pedal, the circuit voltage is 12 volts. This signal tells the CAB that the pedal is depressed. The brake lamp switch is located on the brake pedal under the driver dash. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 915 Brake Light Switch: Testing and Inspection Fig.2 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohm-meter The ohmmeter is used to check continuity between the pin terminals. SWITCH CIRCUIT IDENTIFICATION - Terminals 1 and 2 brake lamp circuit - Terminals 3 and 4 RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6 speed control circuit SWITCH CONTINUITY TEST NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2 Replace switch if meter indicates no continuity With switch plunger retracted, attach test leads to pins 3 and 4 Replace switch if meter indicates no continuity With switch plunger retracted, attach test leads to pins 5 and 6 Replace switch if meter indicates no continuity Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 916 Brake Light Switch: Service and Repair REMOVAL Fig.3 Brake Lamp Switch & Bracket 1. Disconnect the switch harness 2. Press and hold the brake pedal in applied position 3. Rotate the switch counterclockwise about 30° to align the switch lock tab with the notch in bracket 4. Pull the switch rearward out of the mounting bracket and release the brake pedal. INSTALLATION 1. Press and hold the brake pedal down. 2. Align the tab on the new switch with the notch in the switch bracket. Insert the switch in the bracket and turn it clockwise about 30° to lock it in place. 3. Connect the harness wires to the switch. 4. Release the brake pedal. 5. Move the release lever on the switch parallel with the connector to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications Combination Switch: Specifications Steering Column Multi-function Switch Screws 9 ft. lbs. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 920 Multi-Function Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 921 Combination Switch: Description and Operation TURN SIGNAL SYSTEM The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned off by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either camlobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 922 Combination Switch: Testing and Inspection To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. Multi-Function Switch Tests 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 923 Combination Switch: Service and Repair REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. 3. Disconnect the wire connector from the back of the multi-function switch. Fig.15 Multifunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clockspring to the multifunction switch. INSTALLATION 1. Install the clockspring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Fig.42 Standard Cab Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 927 Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 931 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 932 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 933 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 935 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 937 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 938 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 939 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 940 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 941 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 942 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 944 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 950 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Door Switch: Connector Views Door Ajar Switch Driver (Base) Door Ajar Switch Left Rear (Base) Door Ajar Switch Passenger (Base) Door Ajar Switch Right Rear (Base) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Door Switch: Electrical Diagrams The Instrument Panel Gauges and Warning Indicators are not controlled by individual circuits. The ElectroMechanical Instrument Cluster (EMIC) assembly is driven by the BCM via the Programmable Communications Interface (PCI) data bus. For additional information on how the system operates, See: Instrument Panel, Gauges and Warning Indicators/Description and Operation For diagnosis of the EMIC/MIC, See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Door Ajar System Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 954 Door Switch: Description and Operation The Instrument Panel Gauges and Warning Indicators are not controlled by individual circuits. The ElectroMechanical Instrument Cluster (EMIC) assembly is driven by the BCM via the Programmable Communications Interface (PCI) data bus. For additional information on how the system operates, See: Instrument Panel, Gauges and Warning Indicators/Description and Operation For diagnosis of the EMIC/MIC, See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Instrument Cluster when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Refer to the Body section under Doors for the removal and installation procedure. The door ajar switches close a path to ground for the Instrument Cluster when a door is opened. The passenger front door is connected in a parallel-series circuit between ground and the Instrument Cluster, while the driver side front door ajar switch is connected in series between ground and the Instrument Cluster to provide a unique input. The Instrument Cluster reads the switch status, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations Glove Box Lamp Switch: Locations Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 958 Fig.40 Right Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 959 Glove Box Lamp and Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Locations > Page 960 Glove Box Lamp Switch: Service and Repair GLOVE BOX LAMP/SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove the glove box from the instrument panel. Fig. 3 Glove Box Lamp And Switch Remove/Install 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. 6. Close the glove box 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service Precautions Hazard Warning Switch: Service Precautions WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service Precautions > Page 964 Hazard Warning Switch: Description and Operation The hazard switch is activated by a push button located in the multifunction switch on the top of the steering column between the steering wheel and instrument cluster. The hazard warning system allows the vehicle operator to provide other vehicle operators in the near proximity an optical indication that the vehicle is disabled or an obstacle to traffic flow. The hazard warning system has battery voltage at all times, regardless of ignition position. The instrument cluster monitors the multiplexed multifunction switch operation. When the hazard warning switch is activated, the instrument cluster will send a J1850 bus message to the Front Control Module (FCM), then activate the two turn signal indicators and audible click in the instrument cluster. The FCM will then activate the necessary relays in the Power Distribution Center (PDC) to begin flashing both the front and rear turn signal indicator lamps. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service Precautions > Page 965 Hazard Warning Switch: Testing and Inspection MULTI FUNCTION SWITCH Multi-Function Switch Tests To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service Precautions > Page 966 Hazard Warning Switch: Service and Repair MULTI FUNCTION SWITCH REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. Fig. 12 MultiFunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multi-function switch. INSTALLATION WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations Headlamp Switch: Component Locations The multiplexed headlamp switch is located on the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 971 Headlamp Switch: Connector Locations Fig.34 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 972 Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Component Locations > Page 973 Fig.39 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 974 Headlamp Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 975 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 976 Headlamp Switch: Description and Operation The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps. A separate switch in the module controls the interior lamps and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the cluster lamps. The multiplexed headlamp switch has an off, parking lamp, fog lamp and a headlamp on position. High beams are controlled by the multiplexed multifunction switch on the steering column. The fog lamps are illuminated by pulling back on the headlamp switch knob when in the parking lamp or headlamp ON position.The headlamp switch cannot be repaired. It must be replaced. The Instrument Cluster monitors the headlamp and multifunction switch operation. When the headlamp switch is rotated to the parking lamp or On position the Instrument Cluster sends a J1850 message to the Front Control Module, which is mated to the power distribution center to become the Integrated Control Module, to illuminate the appropriate bulbs. When the multifunction switch is activated to the optical horn or high beam position the Instrument Cluster illuminates the high beam indicator and sends a J1850 message to the Front Control Module to illuminate the appropriate bulbs. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 977 Headlamp Switch: Adjustments ADJUSTMENTS Headlamps can be aligned using the screen method provided in this section. Alignment Tool C-4466-A or equivalent can also be used. Refer to instructions provided with the tool for proper procedures. LAMP ALIGNMENT SCREEN PREPARATION Fig.11 Headlamp Alignment Screen - Typical 1. Position vehicle on a level surface perpendicular to a flat wall 7.62 meters (25 ft) away from front of headlamp lens. 2. If necessary, tape a line on the floor 7.62 meters (25 ft) away from and parallel to the wall. 3. Up 1.27 meters (5 feet) from the floor, tape a line on the wall at the centerline of the vehicle. Sight along the centerline of the vehicle (from rear of vehicle forward) to verify accuracy of the line placement. 4. Rock vehicle side-to-side three times to allow suspension to stabilize. 5. Jounce front suspension three times by pushing downward on front bumper and releasing. 6. Measure the distance from the center of headlamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/down adjustment reference. 7. Measure distance from the centerline of the vehicle to the center of each headlamp being aligned. Transfer measurements to screen (with tape) to each side of vehicle centerline. Use these lines for left/ right adjustment reference. VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT 1. Verify headlamp dimmer switch and high beam indicator operation. 2. Correct defective components that could hinder proper headlamp alignment. 3. Verify proper tire inflation. 4. Clean headlamp lenses. 5. Verify that luggage area is not heavily loaded. 6. Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel. HEADLAMP ALIGNMENT A properly aimed low beam headlamp will project top edge of high intensity pattern on screen from 50 mm (2 in.) above to 50 mm (2 in.) below headlamp centerline. The side-to-side outboard edge of high intensity pattern should be from 50 mm (2 in.) left to 50 mm (2 in.) right of headlamp centerline. The preferred headlamp alignment is 1" down for the up/down adjustment and 0 for the left/ right adjustment. The high beam pattern should be correct when the low beams are aligned properly. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 978 To adjust low beam headlamp, rotate alignment screws to achieve the specified aim. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 979 Headlamp Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, 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 AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left instrument panel bezel. 3. Disconnect the harness connector. Fig.9 Headlamp Switch Removal 4. Remove the screws that secure the headlamp switch to the instrument panel bezel. 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION 1. Position the headlamp switch to the left instrument panel bezal and secure with screws.Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the instrument panel wire harness connector for the headlamp switch. 3. Position the left instrument panel bezal on to the instrument panel. 4. Install the cluster bezel onto the instrument panel. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 983 Horn Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 984 Horn Switch: Description and Operation The horn switch is molded into the driver airbag trim cover. The horn switch cannot be serviced separately For service procedures, (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 985 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a DRB III scan tool and the proper Diagnostic Procedures manual. The DRB III scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic modules are sending and receiving the proper messages on the PCI data bus, and that the horns are being sent the proper hard wired outputs for them to perform their functions. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service Precautions Turn Signal Switch: Service Precautions WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service Precautions > Page 989 Turn Signal Switch: Description and Operation MULTI-FUNCTION SWITCH Turn Signal System The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned OFF by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service Precautions > Page 990 Turn Signal Switch: Testing and Inspection MULTI FUNCTION SWITCH Multi-Function Switch Tests To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service Precautions > Page 991 Turn Signal Switch: Service and Repair MULTI FUNCTION SWITCH REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. Fig. 12 MultiFunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multi-function switch. INSTALLATION WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSOR The Accelerator Pedal Position Sensor (APPS) assembly is located under the vehicle battery tray. A cable connects the assembly to the accelerator pedal. A plastic cover with a movable door is used to cover the assembly. The APPS is used only with the 5.7L V-8 engine. The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. A mechanical cable is used between the accelerator pedal and the APPS assembly. Although a cable is used between the pedal and APPS, a mechanical cable is not used at the throttle body. Throttle plate position is electrically determined. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 997 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION SENSOR REMOVAL Fig.2 Apps Location The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the vehicle battery tray. Access to APPS is gained from over top of left / front tire. 1. Disconnect negative battery cable at battery. 2. Disconnect APPS cable at accelerator pedal. Refer to Accelerator Pedal Removal/Installation. 3. Remove wheel house liner at left / front wheel. Refer to Body. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 998 Fig.3 Apps Remove/Install 4. Gain access to APPS electrical connector by opening swing-down door. Disconnect electrical connector. 5. Remove 3 mounting bolts. 6. Remove APPS assembly from battery tray. Fig.4 Apps Cable 7. If cable is to be separated at APPS, unsnap cable clip from ball socket. Release cable from plastic housing by pressing on small cable release tab. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 999 INSTALLATION 1. Install Accelerator Pedal Position Sensor (APPS) cable to accelerator pedal. Refer to Accelerator Pedal Removal/Installation. 2. Connect electrical connector to APPS. 3. If necessary, connect cable to APPS lever ball socket (snaps on). 4. Snap APPS cable cover closed. 5. Position APPS assembly to bottom of battery tray and install 3 bolts. Refer to Torque Specifications. 6. Install wheelhouse liner. Refer to Body. 7. Perform the following procedure: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig. 1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1004 Battery Temperature Sensor: Connector Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1005 Fig.28 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1006 Fig.29 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1007 Fig.30 Integrated Power Module and Fan Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1008 Battery Temperature Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1009 Battery Temperature Sensor: Description and Operation Fig. 1 Battery Temperature Sensor Location BATTERY TEMPERATURE SENSOR The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1010 Battery Temperature Sensor: Testing and Inspection Test 1 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/BATT (out of calibration) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1011 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1). 1. Remove battery Refer to Battery for procedures. 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery Refer to Battery for procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor - 3.7/4.7L ...................................................................................................................................................... 12 Nm (106 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1015 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1016 Camshaft Position Sensor (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1017 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) on this engine is bolted to the right-front side of the right cylinder head. Fig.6 CMP Operation - 3.7L V-6 The Camshaft Position Sensor (CMP) sensor on this engine contains a hall effect device referred to as a sync signal generator. A rotating target wheel (tonewheel) for the CMP is located at the front of the camshaft for the right cylinder head. This sync signal generator detects notches located on a tonewheel. As the tonewheel rotates, the notches pass through the sync signal generator. The signal from the CMP sensor is used in conjunction with the Crankshaft Position Sensor (CKP) to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the tonewheel notch enters the tip of the CMP, the interruption of magnetic field causes the voltage to switch high, resulting in a sync signal of approximately 5 volts. When the trailing edge of the tonewheel notch leaves then tip of the CMP, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1018 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION SENSOR Fig.12 CMP Location - 3.7L The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. REMOVAL 1. Disconnect electrical connector at CMP sensor. 2. Remove sensor mounting bolt. 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to torque specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 - 3.7L V-6 Engine..........................................................................................................................28 Nm 21 Ft. Lbs 205 In. Lbs Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1025 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1026 Crankshaft Position Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1027 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1028 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig.5 CKP Operation - 3.7L V-6 A tonewheel (target wheel) is bolted to the engine crankshaft. This tonewheel has sets of notches 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1029 Crankshaft Position Sensor: Service and Repair REMOVAL Fig.10 CKP Removal/Installation - 3.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. 1. Raise vehicle. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder block. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. 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. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Locations Intake Air Temperature (IAT) Sensor: Locations 3.7L 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Locations > Page 1033 Intake Air Temperature Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Locations > Page 1034 Intake Air Temperature (IAT) Sensor: Description and Operation Intake Air Temperature Sensor The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Locations > Page 1035 Intake Air Temperature (IAT) Sensor: Service and Repair REMOVAL Fig.24 IAT Sensor Location - 3.7L V-6 The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum. 1. Disconnect electrical connector from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Fig.25 IAT Sensor Tab/O-Ring - 3.7L V-6 / 4.7L V-8 / 5.7L V-8 3. Gently lift on small plastic release tab or and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 > Locations > Page 1036 INSTALLATION The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor - 3.7/4.7/5.7L ................................................................................................................ .................................................... 20 Nm (15 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations > Page 1042 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1043 Knock Sensor (3.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1044 Knock Sensor: Description and Operation KNOCK SENSOR The sensors are used only with these engines: On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1045 Knock Sensor: Service and Repair KNOCK SENSOR Fig.39 Knock Sensor - 3.7L V-6 Fig.40 Knock Sensor - 4.7L V-8 The 2 knock sensors are bolted into the cylinder block under the intake manifold. NOTE: The left sensor is identified by an identification tag (LEFT). It is also identified by a larger bolt head. The Powertrain Control Module (PCM) must have and know the correct sensor left/right positions. Do not mix the sensor locations. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1046 1. Disconnect knock sensor dual pigtail harness from engine wiring harness. This connection is made near rear of engine. 2. Remove intake manifold. Refer to Engine section. 3. Remove sensor mounting bolts. Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensors from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting holes. 2. Install sensors into cylinder block. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolts. Refer to torque specification. 4. Install intake manifold. Refer to Engine section. 5. Connect knock sensor wiring harness to engine harness at rear of intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations 3.7L 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1050 Manifold Absolute Pressure Sensor (3.7L/4.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1051 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold with 2 screws. The MAP sensor is used as an input to the Power-train Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1052 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig.31 MAP Sensor - 3.7L V-6 Fig.32 MAP Sensor O-Ring - 3.7L/4.7L The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold. An O-ring is used to seal the sensor to the intake manifold. 1. Disconnect electrical connector at sensor. 2. Clean area around MAP sensor. 3. Remove 2 sensor mounting screws. 4. Remove MAP sensor from intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1053 5. Check condition of sensor O-ring. INSTALLATION The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold. An O-ring is used to seal the sensor to the intake manifold. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Install MAP sensor mounting bolts (screws). Refer to Torque Specifications. 5. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams DIAGRAM LAYOUT 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 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. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. 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 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. Wiring Diagram Symbols SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 Circuit Identification Code Chart CIRCUIT FUNCTIONS 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Wire Code Identification Wire Color Code Chart CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... ...................................... Left Hand Drive Vehicles RHD ..................................................................... .................................................................................................................... Right Hand Drive Vehicles ATX ............................................................................................................................................................. Automatic Transmissions-Front Wheel Drive MTX .............................................................................. ................................................................................... Manual Transmissions-Front Wheel Drive AT . .............................................................................................................................................................. .. Automatic Transmissions-Rear Wheel Drive MT .............................................................................. ...................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .................................................................................................................................................. ............................... Single Over Head Cam Engine DOHC ................................................................ ............................................................................................................... Double Over Head Cam Engine BUX ......................................................................................................................................... ................................................................ Built-Up-Export Built-Up-Export .............................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export .................................................................................................................................... Vehicles Built For Sale In North America Circuit Functions Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 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 Views Information Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location 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: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 - 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. - 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. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 - 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. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 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. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 RHD ..................................................................................................................................................... ........................................ Right Hand Drive Vehicles ATX .................................................................. ............................................................................................... Automatic Transmissions-Front Wheel Drive MTX ............................................................................................................................................ ......................... Manual Transmissions-Front Wheel Drive AT ........................................................... .......................................................................................................... Automatic Transmissions-Rear Wheel Drive MT ................................................................................................................................... ..................................... Manual Transmissions-Rear Wheel Drive SOHC .......................................... ........................................................................................................................................... Single Over Head Cam Engine DOHC ........................................................................................................... ........................................................................ Double Over Head Cam Engine BUX ......................... .............................................................................................................................................................. ...................... Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Fig. 10 Removal Of Dress Cover Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 Oil Pressure Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Engine Oil Pressure Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1082 Oil Pressure Sensor: Service and Repair OIL PRESSURE SENSOR/SWITCH REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise vehicle on hoist. 3. Remove front splash shield. 4. Disconnect oil pressure sender wire (Fig. 71). 5. Remove the pressure sender (Fig. 71). INSTALLATION 1. Install oil pressure sender. 2. Connect oil pressure sender wire. 3. Install front splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations 3.7L 3.7L 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1086 3.7L 4 Sensor Vehicle 2 Sensor Vehicle (1 = Downstream, 2 = Upstream) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1087 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1088 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1089 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. Oxygen Sensor Heater Relay - 5.9L/8.0L: If 4 oxygen sensors are used, a separate heater relay is used to supply voltage to the sensors heating elements for only the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through a Pulse Width Module (PWM) method. Pulse Width Module (PWM) - 5.9L/8.0L: Voltage to the O2 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through two separate Pulse Width Module (PWM) low side drivers. PWM is used on both the upstream and downstream O2 sensors if equipped with a Federal Emissions Package, and only on the 2 upstream sensors (1/1 and 2/1) if equipped with a California Emissions Package. The main objective for a PWM driver is to avoid overheating of the O2 sensor heater element. With exhaust temperatures increasing with time and engine speed, it's not required to have a full-voltage duty-cycle on the O2 heater elements. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13 ohms. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 - 1100 °F (500 - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. Upstream Sensor - Federal Emissions Package: The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. Downstream Sensor - Federal Emissions Package: The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency Upstream Sensors - California Emissions Package: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1090 this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Downstream Sensors - California Emissions Package: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1091 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector; or attempt any soldering of the sensor wiring harness. Fig.39 O2 Sensor System - With 4 Sensors Fig.40 O2 Sensor System - With 2 Sensors WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor Tighten to 30 Nm (22 ft.lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Switch .......................................................................................................................................................... 10 Nm (80 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1095 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1096 Power Steering Pressure Switch (3.7L/4.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1097 Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 9 A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will be used with both 3.7L, 4.7L and 5.7L engines. There is no pressure switch used for the 5.9L pump. OPERATION The switch is used on the 3.7L V-6, 4.7L & 5.7L V-8 engines. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1098 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 9 The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 3.7L V-6 and the 4.7L, 5.7L V-8 engines. 1. Install power steering switch into power steering line. 2. Tighten to 8 - 11 Nm (70 - 100 in. lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams Throttle Position Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1102 Throttle Position Sensor: Description and Operation Throttle Position Sensor The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a seperate TPS on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1103 Throttle Position Sensor: Service and Repair Fig.56 TPS Location - 3.7L V-6 Fig.57 TPS Installation - 3.7L V-6 REMOVAL - 3.7L V-6 The TPS is mounted to the throttle body. 1. Remove air resonator tube at throttle body. 2. Disconnect TPS electrical connector. 3. Remove 2 TPS mounting screws. 4. Remove TPS. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 1104 Fig.61 TPS Installation - 3.7L INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1109 Transmission Position Switch/Sensor: Description and Operation Transmission Solenoid/TRS Assembly TRANSMISSION SOLENOID/TRS ASSEMBLY DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 126). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1110 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1111 TRS Switch States Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSOR The Accelerator Pedal Position Sensor (APPS) assembly is located under the vehicle battery tray. A cable connects the assembly to the accelerator pedal. A plastic cover with a movable door is used to cover the assembly. The APPS is used only with the 5.7L V-8 engine. The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. A mechanical cable is used between the accelerator pedal and the APPS assembly. Although a cable is used between the pedal and APPS, a mechanical cable is not used at the throttle body. Throttle plate position is electrically determined. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 1116 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION SENSOR REMOVAL Fig.2 Apps Location The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the vehicle battery tray. Access to APPS is gained from over top of left / front tire. 1. Disconnect negative battery cable at battery. 2. Disconnect APPS cable at accelerator pedal. Refer to Accelerator Pedal Removal/Installation. 3. Remove wheel house liner at left / front wheel. Refer to Body. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 1117 Fig.3 Apps Remove/Install 4. Gain access to APPS electrical connector by opening swing-down door. Disconnect electrical connector. 5. Remove 3 mounting bolts. 6. Remove APPS assembly from battery tray. Fig.4 Apps Cable 7. If cable is to be separated at APPS, unsnap cable clip from ball socket. Release cable from plastic housing by pressing on small cable release tab. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 1118 INSTALLATION 1. Install Accelerator Pedal Position Sensor (APPS) cable to accelerator pedal. Refer to Accelerator Pedal Removal/Installation. 2. Connect electrical connector to APPS. 3. If necessary, connect cable to APPS lever ball socket (snaps on). 4. Snap APPS cable cover closed. 5. Position APPS assembly to bottom of battery tray and install 3 bolts. Refer to Torque Specifications. 6. Install wheelhouse liner. Refer to Body. 7. Perform the following procedure: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use DRB III Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams Throttle Position Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1122 Throttle Position Sensor: Description and Operation Throttle Position Sensor The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a seperate TPS on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1123 Throttle Position Sensor: Service and Repair Fig.56 TPS Location - 3.7L V-6 Fig.57 TPS Installation - 3.7L V-6 REMOVAL - 3.7L V-6 The TPS is mounted to the throttle body. 1. Remove air resonator tube at throttle body. 2. Disconnect TPS electrical connector. 3. Remove 2 TPS mounting screws. 4. Remove TPS. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1124 Fig.61 TPS Installation - 3.7L INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor - 3.7/4.7L ...................................................................................................................................................... 12 Nm (106 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1129 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1130 Camshaft Position Sensor (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1131 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position Sensor (CMP) on this engine is bolted to the right-front side of the right cylinder head. Fig.6 CMP Operation - 3.7L V-6 The Camshaft Position Sensor (CMP) sensor on this engine contains a hall effect device referred to as a sync signal generator. A rotating target wheel (tonewheel) for the CMP is located at the front of the camshaft for the right cylinder head. This sync signal generator detects notches located on a tonewheel. As the tonewheel rotates, the notches pass through the sync signal generator. The signal from the CMP sensor is used in conjunction with the Crankshaft Position Sensor (CKP) to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the tonewheel notch enters the tip of the CMP, the interruption of magnetic field causes the voltage to switch high, resulting in a sync signal of approximately 5 volts. When the trailing edge of the tonewheel notch leaves then tip of the CMP, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1132 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION SENSOR Fig.12 CMP Location - 3.7L The Camshaft Position Sensor (CMP) on this engine is bolted to the front/top of the right cylinder head. REMOVAL 1. Disconnect electrical connector at CMP sensor. 2. Remove sensor mounting bolt. 3. Carefully twist sensor from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in cylinder head. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into cylinder head with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten. Refer to torque specifications. 5. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 - 3.7L V-6 Engine..........................................................................................................................28 Nm 21 Ft. Lbs 205 In. Lbs Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1136 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1137 Crankshaft Position Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1138 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1139 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig.5 CKP Operation - 3.7L V-6 A tonewheel (target wheel) is bolted to the engine crankshaft. This tonewheel has sets of notches 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. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 1140 Crankshaft Position Sensor: Service and Repair REMOVAL Fig.10 CKP Removal/Installation - 3.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. 1. Raise vehicle. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting bolt. 4. Carefully twist sensor from cylinder block. 5. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. 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. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair REMOVAL The ignition key must be in the key cylinder for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. Fig. 12 4. A retaining pin is located at side of key cylinder assembly. (a) Rotate key to RUN position. Fig. 13 (b) Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor - 3.7/4.7/5.7L ................................................................................................................ .................................................... 20 Nm (15 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 1150 3.7L Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1151 Knock Sensor (3.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1152 Knock Sensor: Description and Operation KNOCK SENSOR The sensors are used only with these engines: On 3.7L V-6 and 4.7L V-8 engines, the 2 knock sensors are bolted into the cylinder block under the intake manifold. On 5.7L V-8 engines, 2 knock sensors are also used. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1153 Knock Sensor: Service and Repair KNOCK SENSOR Fig.39 Knock Sensor - 3.7L V-6 Fig.40 Knock Sensor - 4.7L V-8 The 2 knock sensors are bolted into the cylinder block under the intake manifold. NOTE: The left sensor is identified by an identification tag (LEFT). It is also identified by a larger bolt head. The Powertrain Control Module (PCM) must have and know the correct sensor left/right positions. Do not mix the sensor locations. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1154 1. Disconnect knock sensor dual pigtail harness from engine wiring harness. This connection is made near rear of engine. 2. Remove intake manifold. Refer to Engine section. 3. Remove sensor mounting bolts. Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensors from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting holes. 2. Install sensors into cylinder block. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock senor bolt is relatively light for an 8mm bolt. NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolts. Refer to torque specification. 4. Install intake manifold. Refer to Engine section. 5. Connect knock sensor wiring harness to engine harness at rear of intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 1160 Air Bag Deactivation Switch: Connector Locations Fig.35 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 1161 Fig.37 Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Component Locations > Page 1162 Fig.40 Right Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1163 Passenger Airbag On/Off Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1164 Air Bag Deactivation Switch: Service Precautions WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1165 Air Bag Deactivation Switch: Description and Operation Fig. 38 Passenger Airbag ON/OFF Switch PASSENGER AIRBAG ON/OFF SWITCH The passenger airbag ON/OFF switch is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate and nomenclature and the key cylinder actuator. The "OFF' position of the switch is illuminated when this switch position is selected, while the "ON" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag ON/OFF switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag ON/OFF switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag ON/OFF switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. The ignition key is the only key or object that should ever be inserted into the switch. The ON/OFF switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag ON/OFF switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF indicator), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the OFF indicator will be extinguished and the passenger airbag is enabled. The passenger airbag ON/OFF switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected and to provide circuit diagnostics. The ON/OFF switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the ON/OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. When the switch is in the OFF position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the OFF indicator of the switch. The ACM will also illuminate the OFF indicator of the switch for about 2 seconds each time the ignition switch is turned to the ON position as a bulb test. The ACM will also store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag ON/OFF switch or indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag ON/OFF switch or the ACM, a DRB III scan tool is Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1166 required. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1167 Air Bag Deactivation Switch: Service and Repair PASSENGER AIRBAG ON/OFF SWITCH REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel from the instrument panel. Fig. 39 Passenger Airbag ON/OFF Switch Remove/Install 3. Remove the three screws that secure the passenger airbag ON/OFF switch and face plate unit to the back of the center bezel. 4. Remove the passenger airbag ON/OFF switch and face plate from the center bezel as a unit. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the passenger airbag ON/OFF switch and face plate unit to the back of the center bezel. 2. Install and tighten the three screws that secure the passenger airbag ON/OFF switch face plate to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation NOTE: The Impact Senor and the Safing Sensor are in the control modules, and can not be serviced separately. Airbag Control Module (ACM) The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. Side Impact Airbag Control Module (SIACM) The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation NOTE: The Impact Senor and the Safing Sensor are in the control modules, and can not be serviced separately. Airbag Control Module (ACM) The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. Side Impact Airbag Control Module (SIACM) The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Fig. 46 Seat Belt Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1177 Driver Seat Belt Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1178 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1179 Seat Belt Buckle Switch: Description and Operation Fig. 46 Seat Belt Switch SEAT BELT SWITCH The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track. The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire and connector on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the instrument cluster. When the driver side seat belt tip-half is inserted in the seat belt buckle, the switch closes the path to ground; and, when the driver side seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1180 Seat Belt Buckle Switch: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty seat belt buckle-half assembly 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G640) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations Battery Temperature Sensor: Component Locations Fig. 1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1186 Battery Temperature Sensor: Connector Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1187 Fig.28 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1188 Fig.29 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Component Locations > Page 1189 Fig.30 Integrated Power Module and Fan Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1190 Battery Temperature Sensor Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1191 Battery Temperature Sensor: Description and Operation Fig. 1 Battery Temperature Sensor Location BATTERY TEMPERATURE SENSOR The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1192 Battery Temperature Sensor: Testing and Inspection Test 1 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/BATT (out of calibration) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1193 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1). 1. Remove battery Refer to Battery for procedures. 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery Refer to Battery for procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations Fig.26 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1197 Fig.27 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1198 Clutch Interlock Brake Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1199 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH A clutch pedal position (interlock) switch is used on vehicles equipped with a manual transmisison. The clutch pedal position switch is mounted on the clutch master cylinder push rod (Fig. 22). The switch is actuated by clutch pedal movement. The clutch pedal position switch is used to prevent starter motor engagement unless the clutch pedal is depressed. An input from this switch is also used to either shut down and/or prevent operation of the speed control system when the clutch pedal is depressed. The position switch is an integral part of the clutch master cylinder push rod and is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1200 Clutch Switch: Testing and Inspection DIAGNOSIS AND TESTING - CLUTCH PEDAL POSITION SWITCH 1. Locate clutch switch 2-wire electrical connector. This will be the test point. This connector is attached to pedal support bracket located under instrument panel to left of clutch pedal (Fig. 23). Disconnect wiring at this point. 2. Check for switch continuity with an ohmmeter while operating clutch pedal up and down. Continuity should be broken and reapplied each time pedal is pressed. 3. If continuity is not present, or is always present at any pedal position, replace switch. Switch is not serviced separately Replace clutch master cylinder. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair REMOVAL The ignition key must be in the key cylinder for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. Fig. 12 4. A retaining pin is located at side of key cylinder assembly. (a) Rotate key to RUN position. Fig. 13 (b) Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications Power Steering Pressure Switch: Specifications TORQUE SPECIFICATIONS Power Steering Pressure Switch .......................................................................................................................................................... 10 Nm (80 in. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 1210 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 1211 Power Steering Pressure Switch (3.7L/4.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 1212 Power Steering Pressure Switch: Description and Operation DESCRIPTION Fig. 9 A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will be used with both 3.7L, 4.7L and 5.7L engines. There is no pressure switch used for the 5.9L pump. OPERATION The switch is used on the 3.7L V-6, 4.7L & 5.7L V-8 engines. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 1213 Power Steering Pressure Switch: Service and Repair REMOVAL Fig. 9 The power steering pressure switch is installed in the power steering high-pressure hose. 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use back-up wrench on power steering line to prevent line bending. INSTALLATION This switch is used only with the 3.7L V-6 and the 4.7L, 5.7L V-8 engines. 1. Install power steering switch into power steering line. 2. Tighten to 8 - 11 Nm (70 - 100 in. lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1219 Line Pressure Sensor (3.7/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1220 Fluid Pressure Sensor/Switch: Description and Operation LINE PRESSURE (LP) SENSOR DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1221 Pressure Switch States Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1222 Fluid Pressure Sensor/Switch: Service and Repair LINE PRESSURE (LP) SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 92). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1226 Overdrive Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1227 Overdrive Switch: Description and Operation OVERDRIVE SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the shift lever arm (Fig. 106). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1228 Overdrive Switch: Service and Repair REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 107). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 108) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1229 2. Install the overdrive off switch into the connector (Fig. 109) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1234 Transmission Position Switch/Sensor: Description and Operation Transmission Solenoid/TRS Assembly TRANSMISSION SOLENOID/TRS ASSEMBLY DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 126). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1235 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1236 TRS Switch States Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Bolt, input speed sensor ...................................................................................................................... ............................................. 11.8 Nm (105 inch lbs.) Bolt, output speed sensor ................................ ................................................................................................................................. 11.8 Nm (105 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1240 Fig.14 Transmission 45RFE (4X4) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor Input Speed Sensor (3.7/4.7/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 1243 Output Speed Sensor (3.7/4.7/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor Transmission Speed Sensor: Description and Operation Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Input Speed Sensor > Page 1246 Transmission Speed Sensor: Description and Operation Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor INPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 91). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 1249 Transmission Speed Sensor: Service and Repair Output Speed Sensor OUTPUT SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 105). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor TRANSMISSION TEMPERATURE SENSOR DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor > Page 1254 Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor > Page 1255 Transmission Temperature Sensor/Switch: Description and Operation Transmission Solenoid/TRS Assembly TRANSMISSION SOLENOID/TRS ASSEMBLY DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly (Fig. 126). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES: Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor > Page 1256 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1261 Power Window Switch: Diagrams Door Window/Lock Switch Passenger Power Window Switch Left Rear Power Window Switch Right Rear Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1262 Power Window Switch: Description and Operation The power window switches control the battery and ground feeds to the power window motors. The passenger door power window switches receive their battery and ground feeds through the circuitry of the drivers window switch. When the power window lockout switch is in the Lock position, the battery feed for the passenger door window switches is interrupted. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1263 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED (s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin- out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Unplug the wire harness connector from the switch unit. Passenger Door Switch 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1264 Power Window Switch: Service and Repair REMOVAL Front Passenger 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, gently pry the switch from the door trim panel. 3. Disconnect the electrical harness connector from the window switch. Rear Passenger 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION Front Passenger 1. Connect electrical harness connector to switch. 2. Position switch to door trim panel. 3. Connect battery negative cable. Rear Passenger 1. Install switch to door trim panel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Fig.25 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1269 Fig.29 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1270 Fig.30 Integrated Power Module and Fan Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1271 Washer Fluid Level Switch Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1272 Washer Fluid Level Switch: Description and Operation Fig.6 Washer Fluid Level Switch WASHER FLUID LEVEL SWITCH The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the of the washer reservoir in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. A small, molded plastic float has two pivot pins near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the switch nipple formation. A small magnet is secured within the end of the float nearest the switch nipple formation, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except V-10 and diesel engines) or left (V-10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FMC senses the ground on the washer fluid switch sense circuit. The FMC is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicator requires the use of a DRBIII scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1273 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig.7 Washer Fluid Level Switch Remove/Install - Except V-10 & Diesel Engine Fig.8 Washer Fluid Level Switch Remove/Install - V-10 & Diesel Engine 4. Disconnect the right (except V-10 and diesel engine) or left (V-10 and diesel engine only) headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1274 NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the reservoir sump. Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the right (except V-10 and diesel engine) or left (V-10 and diesel engine only) headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose to the barbed outlet nipple of the washer pump/motor unit. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1279 Alignment: Description and Operation DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Fig. 1 Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 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 (LD only). 7. Road test the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1282 Alignment: Service and Repair Wheel Alignment Alignment Link/Coil Suspension STANDARD PROCEDURE - ALIGNMENT LINK/COIL SUSPENSION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Fig. 5 Caster can be adjusted by rotating the cams on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Camber and Caster Adjustment STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1283 Fig. 3 Camber and caster angle adjustments involve changing the position of the upper control arm in conjunction with the slotted holes in the frame brackets, Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. Camber, Caster and Toe Adjustment STANDARD PROCEDURE - CAMBER,CASTER AND TOE ADJUSTMENT NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Fig. 3 Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1284 CASTER Moving the front or rear position of the upper control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height. To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Fig. 4 3. Adjust the wheel toe position by turning the inner tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Toe Adjustment STANDARD PROCEDURE - TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1285 Fig. 4 3. Adjust the wheel toe position by turning the inner tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1286 Alignment: Service and Repair Curb Height Measurement Chrysler does not give ride height specifications for this vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Page 1287 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel System Pressure: .................................................................................................................................................. 339 kPa ± 34 kPa (49.2 psi ± 2 psi). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1292 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1293 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1301 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Firing Order - 3.7L V-6 Firing Order 1-6-5-4-3-2 Cylinder Numbering Front to back Left Bank 1-3-5 - Right Bank 2-4-6 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1306 Firing Order - 3.7L V-6 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 3.7L V-6 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type Spark Plug: Specifications Spark Plug Type Spark Plug Type .................................................................................................................................. ................................................... ZFR6F-11G (NGK) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type > Page 1315 Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... ...................................................... 1.1 mm (0.042 in.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type > Page 1316 Spark Plug: Specifications Spark Plug Torque Spark Plugs - 3.7/4.7L ......................................................................................................................... ..................................................... 27 Nm (20 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1317 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ................................................... ZFR6F-11G (NGK) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1318 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1319 Spark Plug: Testing and Inspection SPARK PLUGS To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. 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. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. Inaccurate readings will result. Fig.42 Normal Operation And Cold (Carbon) Fouling NORMAL OPERATION The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. COLD FOULING/CARBON FOULING Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). WET FOULING OR GAS FOULING A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1320 Fig.43 Oil Or Ash Encrusted OIL OR ASH ENCRUSTED If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.44 Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1321 Fig.45 Scavenger Deposits SCAVENGER DEPOSITS Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig.46 Chipped Electrode Insulator CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1322 Fig.47 Preignition Damage PREIGNITION DAMAGE Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig.48 Spark Plug Overheating SPARK PLUG OVERHEATING Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Replacement Spark Plug: Service and Repair Spark Plug Replacement REMOVAL Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary. 5. Inspect spark plug condition. Refer to Diagnostics and Testing - Spark Plug Conditions. 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. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs. Refer to torque specifications. 3. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 4. Install ignition coil(s). Refer to Ignition Coil Removal/Installation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Replacement > Page 1325 Spark Plug: Service and Repair Spark Plug Cleaning and Adjustment CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Fig.51 Setting Spark Plug Gap - Typical Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications All gauge pressure indications should be equal, with no more than 25% leakage. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1329 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system (Refer to FUEL SYSTEM/FUEL DELIVERY - DESCRIPTION). 5. Remove the ASD relay (Refer to ELECTRICAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL). 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. 8. (Refer to ENGINE - SPECIFICATIONS) for the correct engine compression pressures. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1333 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 7), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 7). Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1334 Part 1 Of 2 Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1335 Part 2 Of 2 Accessory Drive Belt Diagnosis Chart Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1336 Drive Belt: Service and Repair DRIVE BELTS 3.7L/4.7L REMOVAL CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREEARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER. Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner. 1. Disconnect negative battery cable from battery. 2. Rotate belt tensioner until it contacts it's stop. Remove belt, then slowly rotate the tensioner into the freearm position. (Fig. 8). INSTALLATION Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring loaded) belt tensioner. 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 8). 2. Install new belt (Fig. 8). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1337 3. With the drive belt installed, inspect the belt wear indicator (Fig. 9). On 4.7L Engines only, the gap between the tang and the housing stop (measurement A) must not exceed 24 mm (0.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > 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 1350 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > 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 1356 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1357 Fluid Filter - A/T: Specifications Screw, primary fluid filter ..................................................................................................................... ................................................... 4.5 Nm (40 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 STANDARD PROCEDURE - FLUID LEVEL 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 transmission 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. 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. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 70' F fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up DRB6 scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. (Fig. 66) 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1360 Fluid Filter - A/T: Service and Repair Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT 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. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screw holding filter to valve body (Fig. 67). 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Remove and discard the oil filter seal from the bottom of the oil pump. 12. If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to diagnosis. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION 1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold filter to valve body (Fig. 67). Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter onto the transmission, if necessary. Torque the filter to 14.12 Nm (125 inch lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with Mopar ATF +4. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1361 Fluid Filter - A/T: Service and Repair Transmission Fill STANDARD PROCEDURE - 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 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) 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 Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1366 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL Fig.32 Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 32). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 32). The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/Installation. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair OIL FILTER REMOVAL All engines are equipped with a high quality fullflow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise (Fig. 79) to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 80) hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C COMPRESOR LINE MANIFOLD FASTENER 28 (+/- 6) Nm 21 (+/- 4) Ft. Lbs 250 (+/- 50) In. Lbs) SUCTION LINE TO ACCUMULATOR FITTING 9 Nm 6.6 Ft. Lbs 80 In. Lbs Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1377 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry All tools and equipment must be designed for R-134a refrigerant. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1378 Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from an exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with either 3 - O-ring spring lock couplings or dual axes seals. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure transducer. Fig. 5 A/C Discharge Line 4. Disconnect the discharge line refrigerant line fitting from the condenser inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Disconnect the connection that secures the suction line fitting to the accumulator outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screw that secures the suction and discharge line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the tape or plugs from the suction and discharge line manifold and the compressor. Install the suction and discharge line manifold to the compressor. Tighten the fastener to 28 Nm (250 in. lbs.). 2. Remove the tape or plugs from the suction line and the accumulator outlet fittings. Install the suction line to the accumulator outlet and install fastener. 3. Remove the tape or plugs from the refrigerant line fittings on the discharge line and the condenser inlet tube. Connect the discharge line refrigerant line coupler to the condenser inlet tube. 4. Plug in the wire harness connector to the high pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1381 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Disconnect the liquid line refrigerant line couplers at the condenser outlet and the evaporator inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. Fig. 6 A/C Liquid Line 4. Disengage any clips that secure the liquid line to the inner fender shield or cross brace.. 5. Remove the liquid line from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Install the liquid line into any clips on the inner fender shield and the dash panel. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator. 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1382 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c high pressure transducer. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the suction and discharge line assembly from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 Nm (180 in. lbs.). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting bolt to 22 Nm (200 in. lbs.). 4. Plug in the wire harness connector to the A/C high pressure transducer. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Line Pressure Line ....................................................................................................................................................... 32 Nm (23 ft. lbs.) Power Steering Line Return Line .......................................................................................................................................................... 71 Nm (52 ft. lbs.) Power Steering Line Pressure Line To Pump ....................................................................................................................................... 37 Nm (27 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Independent Front Suspension Power Steering Line/Hose: Service and Repair Independent Front Suspension REMOVAL - RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. Fig. 6 4. Disconnect the return hose at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. REMOVAL - PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. REMOVAL - RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION - RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose at the gear. Tighten the hose to 71 Nm (52 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. INSTALLATION - PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Independent Front Suspension > Page 1388 INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Independent Front Suspension > Page 1389 Power Steering Line/Hose: Service and Repair Link/Coil Front Suspension REMOVAL - RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. Fig. 7 4. Disconnect the return hose at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. REMOVAL - PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. Fig. 8 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Independent Front Suspension > Page 1390 REMOVAL - RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION - RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose at the gear. Tighten the hose to 71 Nm (52 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. INSTALLATION - PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the Full mark on the brake fluid reservoir. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1396 Brake Fluid: Fluid Type Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1397 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1398 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .......................................... 15.4 Liters ( 16.2 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1403 Coolant: Fluid Type Specifications Coolant Types This vehicle has been factory filled with an Ethylene Glycol-based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula, P/N 5011764AB or equivalent. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37 °C (-35 ° F). Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1404 Coolant: Description and Operation ENGINE COOLANT DESCRIPTION - ENGINE COOLANT ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37 °C (-35 °F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7 °C (-90 °F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 °C (300 °F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 °C (-8 °F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 °C (-26 °F). 5 °C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125 °C (257 °F ) at 96.5 kPa (14 psi), compared to 128 °C (263 °F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. DESCRIPTION - HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37 °C (-35 °F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar Antifreeze/Coolant, 5 Year/10O,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149 °C (300 °F). This temperature is hot enough to melt Dodge Ram 1500 2wd Workshop Manual (Truck V6-3.7L VIN K (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1405 plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22 °C (-8 °F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37 °C (-34 °F). The antifreeze concentration must always be a minimum of 44 percent, year round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 °C (-90 °F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37 °C (-35 ° F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.